Gas Composition Sensing Using Carbon Nanotube Arrays

A typical sensor device includes a set of interdigitated microelectrodes fabricated by photolithography on silicon wafer or an electrically insulating substrate. In preparation for fabricating the SWCNT portion of such a sensor, a batch of treated (coated or doped) SWCNTs is dispersed in a solvent. The resulting suspension of SWCNTs is drop-deposited or injected onto the area containing the interdigitated electrodes. As the solvent evaporates, the SWCNTs form a mesh that connects the electrodes. The density of the SWCNTs in the mesh can be changed by varying the concentration of SWCNTs in the suspension and/or the amount of suspension dropped on the electrode area. To enable acquisition of measurements for comparison and to gain orthogonality in the sensor array, undoped SWCNTs can be similarly formed on another, identical set of interdigitated electrodes. Coating materials tested so far include chlorosulfonated polyethylene. Dopants that have been tested include Pd, Pt, Au, Cu and Rh nanoparticle clusters. To date, the sensor has been tested for NO2, NH3, CH4, Cl2, HCl, toluene, benzene, acetone, formaldehyde and nitrotoulene.

This instrument uses a variation of laser heterodyne radiometer (LHR) to measure the concentration of trace gases in the atmosphere by measuring their absorption of sunlight in the infrared. Each absorption signal is mixed with laser light (the local oscillator) at a near-by frequency in a fast photoreceiver. The resulting beat signal is sensitive to changes in absorption, and located at an easier-to-process RF frequency. By separating the signal into a RF filter bank, trace gas concentrations can be found as a function of altitude.

A resistor-type sensor was fabricated which has a network of cross-linked SWCNTs with purity over 99%. An ordinary cellulose paper used for filtration was employed as the substrate. The filter paper exhibits medium porosity with a flow rate of 60 mL/min and particle retention of 5-10m. The roughness and porosity of the papers are attractive because they increase the contact area with the ambient air and promote the adhesion to carbon nanotubes. The SWCNTs were functionalized with carboxylic acid (COOH) to render them hydrophilic, thus increasing the adhesion with the substrate. The functionalized SWCNTs were dispersed in dimethylformamide solution. The film composed of networks of cross-linked CNTs was formed using drop-cast coating followed by evaporation of the solvent. Adhesive copper foil tape was used for contact electrodes. Our sensors outperformed the oxide nanowire-based humidity sensors in terms of sensitivity and response/recovery times.

A hybrid thin film is fabricated by a simple drop-casting method. Functionalized single-walled carbon nanotubes (SWCNTs) and gold nanoparticles (AuNPs) with a diameter of ≈15 nm are drop-casted onto a printed circuit board (PCB) substrate equipped with interdigitated electrodes. The addition of AuNPs to the carbon nanotube networked films enhance sensitivity and lower the detection limit to low parts-per-billion (ppb) concentrations. The gold particle to carbon nanotube ratio is optimized to find the optimum gold nanoparticle loading. The composite films were tested in both air and nitrogen environments across a wide relative humidity range (0-97%), which is suitable for dissolved Nitric Oxide (NO) detection in sea water for oceanographic study and for human breath analysis in medical diagnosis. The sensors exhibited high selectivity, particularly to NO, outperforming other tested gases. Notably, the sensor reliably detected NO at 10 ppb levels with response times within 10 seconds and recovery time around 1 minute, showcasing excellent reproducibility across sensors and operational efficiency within diverse humidity conditions.

The technology is a solid state, Carbon Dioxide (CO2) sensor configured for sensitive detection of CO2 having a concentration within the range of about 100 Parts per Million (ppm) and 10,000 ppm in both dry conditions and high humidity conditions (e.g., > 80% relative humidity). The solid state CO2 sensor achieves detection of high concentrations of CO2 without saturation and in both dynamic flow mode and static diffusion mode conditions. The composite sensing material comprises Oxidized Multi-Walled Carbon Nanotubes (O-MWCNT) and a metal oxide, for example O-MWCNT and iron oxide (Fe2O3) nanoparticles. The composite sensing material has an inherent resistance and corresponding conductivity that is chemically modulated as the level of CO2 increases. The CO2 gas molecules absorbed into the carbon nanotube composites cause charge-transfer and changes in the conductive pathway such that the conductivity of the composite sensing material is changed. This change in conductivity provides a sensor response for the CO2 detection. The solid state CO2 sensor is well suited for automated manufacturing using robotics and software controlled operations. The solid state CO2 sensor does not utilize consumable components or materials and does not require calibration as often as conventional CO2 sensors. Since the technology can be easily integrated into existing programmable electronic systems or hardware systems, the calibration of the CO2 sensor can be automated.