Large-area transparent conductive coatings including alloyed carbon nanotubes and nanowire composites, and methods of making the same
View Patent ↗Certain example embodiments of this invention relate to large-area transparent conductive coatings (TCCs) including carbon nanotubes (CNTs) and nanowire composites, and methods of making the same. The σ dc /σ opt ratio of such thin films may be improved via stable chemical doping and/or alloying of CNT-based films. The doping and/or alloying may be implemented in a large area coating system, e.g., on glass and/or other substrates. In certain example embodiments, a CNT film may be deposited and then doped via chemical functionalization and/or alloyed with silver and/or palladium. Both p-type and n-type dopants may be used in different embodiments of this invention. In certain example embodiments, silver and/or other nanowires may be provided, e.g., to further decrease sheet resistance. Certain example embodiments may provide coatings that approach, meet, or exceed 90% visible transmission and 90 ohms/square target metrics.
1. A method of making a coated article comprising a substrate supporting a carbon nanotube (CNT) inclusive thin film, the method comprising:
providing a CNT-inclusive ink;
applying the ink to the substrate to form an intermediate coating;
providing a material over the intermediate coating;
preparing a solution of PdCl 2 ;
exposing the intermediate coating to the solution of PdCl 2 so that the Pd nucleates at junctions within the intermediate coating, thereby reducing porosity in the intermediate coating in forming the CNT-inclusive thin film; and
applying an overcoat or passivation layer over the intermediate coating following the exposing.
2. The method of claim 1 , further comprising adjusting rheological properties of the CNT-inclusive ink by adding surfactants to the ink so that any semiconducting CNTs located within the ink are less likely to clump together.
3. The method of claim 2 , further comprising using a slot die apparatus to apply the ink having the adjusted rheological properties to the substrate.
4. The method of claim 1 , further comprising drying the intermediate coating or allowing the intermediate coating to dry.
5. The method of claim 1 , wherein the material provided over the intermediate coating is PVP.
6. The method of claim 1 , further comprising doping the intermediate coating so as to chemically functionalize the intermediate coating in forming the CNT-inclusive thin film.
7. The method of claim 1 , wherein reducing porosity in the coating reduces sheet resistance.
8. The method of claim 7 , wherein the sheet resistance is reduced while visible transmission remains relatively unchanged.
9. The method of claim 1 , wherein the overcoat or passivation layer comprises PEDOT:PSS, zirconia, a silicon-based thin film, a polymer, and/or a resins.
10. The method of claim 1 , further comprising substantially planarizing the CNT-inclusive film to reduce surface roughness.
11. The method of claim 10 , wherein the CNT-inclusive film is substantially planarized via the overcoat or passivation layer.
12. The method of claim 10 , wherein the CNT-inclusive film is substantially planarized via deposition of an additional layer.
13. The method of claim 1 , further comprising
providing a silvering solution; and
exposing the intermediate coating to the silvering solution to short junctions in the intermediate coating.
14. The method of claim 13 , wherein exposing of the intermediate coating to the silvering solution is performed after exposing the intermediate coating to the solution of PdCl 2 .
15. The method of claim 1 , further comprising
preparing a silvering solution by dissolving silver nitrate in deionized water; and
exposing the intermediate coating to the silvering solution to short junctions in the intermediate coating.
16. The method of claim 15 , wherein exposing of the intermediate coating to the silvering solution is performed after exposing the intermediate coating to the solution of PdCl 2 .
17. A method of making a coated article comprising a substrate supporting a carbon nanotube (CNT) inclusive thin film, the method comprising:
providing a CNT-inclusive ink, the CNT-inclusive ink comprising double-wall nanotubes;
applying the ink to the substrate to form an intermediate coating using a slot die apparatus;
drying the intermediate coating or allowing the intermediate coating to dry;
providing an adhesion-promoting layer over the intermediate coating;
doping the intermediate coating with a salt and/or super acid so as to chemically functionalize the intermediate coating;
providing a solution of PdCl 2 ;
exposing the intermediate coating to the solution of PdCl 2 so that the Pd nucleates at junctions within the intermediate coating, thereby reducing porosity in the intermediate coating in forming the CNT-inclusive thin film; and
applying an overcoat or passivation layer over the intermediate coating following the exposing.
18. The method of claim 17 , further comprising substantially planarizing the CNT-inclusive film.
19. The method of claim 17 , further comprising
providing a silvering solution; and
exposing the intermediate coating to the silvering solution to short junctions in the intermediate coating.
20. The method of claim 19 , wherein exposing of the intermediate coating to the silvering solution is performed after exposing the intermediate coating to the solution of PdCl 2 .
21. A method of making a coated article comprising a substrate supporting a carbon nanotube (CNT) inclusive thin film, the method comprising:
providing a CNT-inclusive ink, the CNT-inclusive ink comprising double-wall nanotubes;
applying the ink to the substrate to form an intermediate coating using a slot die apparatus;
drying the intermediate coating or allowing the intermediate coating to dry;
providing an adhesion-promoting layer over the intermediate coating;
providing a solution of PdCl 2 ;
exposing the intermediate coating to the solution of PdCl 2 so that the Pd nucleates at junctions within the intermediate coating, thereby reducing porosity in the intermediate coating;
providing a silvering solution;
exposing the intermediate coating to the silvering solution to short junctions in the intermediate coating in forming the CNT inclusive thin film; and
applying an overcoat or passivation layer over the intermediate coating following the exposing.
22. The method of claim 21 , further comprising doping the intermediate coating with a salt and/or super acid so as to chemically functionalize the intermediate coating.
23. The method of claim 21 , wherein exposure to the solution of PdCl 2 and silvering solutions is performed on a mirror line.