Carbon Nanotube Array Sensor Metallphilic Adhesion Layer

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Solution Overview

Problem

Conventional carbon nanotube array sensors face decreased sensitivity and precision due to poor wettability between gold slurry and carbon nanotubes, leading to inadequate conductive capacity and firm connection between nanotubes and electrodes.

Innovation Solution

The solution involves depositing metallophilic layers on the ends of carbon nanotubes, which are then electrically connected to conductive metal layers, ensuring good wettability and firm attachment to electrodes, eliminating the need for conductive slurry and enhancing sensor stability and precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If gold slurry is used to adhere carbon nanotube array to electrodes, then the carbon nanotube array can be connected to electrodes, but the conductive capacity between carbon nanotube array and electrodes is decreased

Engineering Contradiction:

Improveconnection between carbon nanotube array and electrodesVSAvoidsensitivity and precision of sensor

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent introduces an adhesion layer as an intermediary between the carbon nanotube array and the electrode. This adhesion layer serves as a mediator that simultaneously provides both mechanical adhesion and electrical conductivity, resolving the contradiction by eliminating the need for non-conductive gold slurry while maintaining firm connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the material parameter of the interface layer from insulative gold slurry to conductive adhesion layer. This parameter change transforms the interface from having poor conductivity to having good conductivity, thereby improving measurement precision while maintaining reliable connection.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If gold slurry is used to connect carbon nanotube array to electrodes, then connection is established, but firm connection is not achieved due to bad wettability

Engineering Contradiction:

Improvefirm connection between carbon nanotube array and electrodesVSAvoidwettability between connection material and carbon nanotube array

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The adhesion layer acts as an intermediary that is specifically designed to have good wettability with both the carbon nanotube array and the electrode substrate. This intermediary material facilitates firm adhesion through its surface properties, solving the wettability problem that plagues direct gold slurry application.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conductive slurry is used for connection, then electrical connection is achieved, but conductive capacity is decreased due to insulative solvent and binder

Engineering Contradiction:

Improveelectrical connection between carbon nanotube array and electrodesVSAvoidconductive capacity

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent extracts and removes the insulative components (solvent and binder) from the connection interface by replacing the slurry-based approach with a pure conductive adhesion layer. This extraction eliminates the harmful insulative elements while preserving the essential electrical connection function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the conductivity parameter of the interface layer by replacing composite slurry material with pure conductive adhesion layer material. This parameter transformation increases the conductive capacity from poor to good, directly addressing the measurement precision issue.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach improves the sensitivity and precision of carbon nanotube array sensors by ensuring a strong and stable connection between carbon nanotubes and electrodes, thereby prolonging sensor lifespan and enhancing gas molecule detection capabilities.

Implementation Method 1

depositing metallophilic layers on the ends of carbon nanotubes

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 2

forming a conductive metal layer on a surface of each electrode

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 3

The first ends of the carbon nanotubes can be adhered to the conductive metal layer

Methodology Applied

Scientific Effectvan der Waals force: Van der Waals Force

Data Source

PatentUS9068923B2Method for fabricating carbon nanotube array sensor

Publication Date: 2015.06.30 HON HAI PRECISION INDUSTRY CO LTD

AI summary

A method of fabricating a carbon nanotube array sensor includes the following steps. A carbon nanotube array, a first electrode and a second electrode are provided, the carbon nanotube array includes a plurality of carbon nanotubes. Each of the carbon nanotubes includes a first end and a second end opposite to the first end. A first metallophilic layer is formed on the first end of each of the carbon nanotubes. At least one first conductive metal layer is arranged between the first metallophilic layer and the first electrode to electrically connect each of the carbon nanotubes with the first electrode. A second metallophilic layer is formed on the second end of each of the carbon nanotubes. At least one second conductive metal layer is arranged between the second metallophilic layer and the second electrode to electrically connect each of the carbon nanotubes with the second electrode.