Graphitic Structures by Design

It is shown that self-supporting graphitic structures of specific shape can be grown in a variety of forms, from nanoscale to macroscale, on metal templates, in a fuel-rich mixture of ethylene and oxygen at temperatures between 750 and 900 K. The evidence presented suggests graphite can be grown in any shape created from catalytic metals (e.g., Ni) under the proper conditions of temperature and gas composition. Structures produced include macroscale bodies, centimeters in dimension, composed of micrometer-scale graphite elements such as graphite "foam" and regular graphite "lattices". Nanoscale hollow graphite spheres were also produced. The production rate in the apparatus employed was roughly shown to be 1 layer/s and was steady with time over several hours. The process of producing self-supporting bodies generally produces hollow graphite structures, as the underlying metal template must be removed by acid following the completion of graphite growth. The process is believed to be possible only in an environment, such as combustion, in which a high concentration of particular radical species is present in the vicinity of the template surface. The following process is postulated: (i) a single layer of graphite is formed from gas-phase radicals by the catalytic action of the metal template, (ii) additional graphite growth is "autocatalytic" and occurs via the decomposition of radicals on the surface and the incorporation of "free" carbon atoms, or other radical fragments, into "edge sites" on the graphite surface.