Abstract
Owing to their extraordinary physicochemical, electrical, and mechanical properties, carbon nanotubes (CNTs) and graphene materials have been widely used to improve energy storage and conversion. In this article, we briefly review the latest development on fabrication of 3D porous structures of CNTs or graphene sheets or their hybrids, and their applications in various energy devices including supercapacitors, (bio-) fuel cells, and lithium ion batteries.
Introduction
In the past decades, carbon nanotubes (CNTs) and graphen have changed the landscape of many fields in science and technology, including energy storage and conversion (Sun et al., ; Liu et al., ; Weiss et al., ; Jariwala et al., ; Zhang et al., ). Although differing in structure, synthetic routes, and physicochemical properties, the two carbon allotropes share common merits for energy applications, such as good electrical conductivity, high-specific surface area, excellent mechanical strength, and flexibility. In frequent cases, integration of 1D CNT and 2D graphene materials exerts synergistic effects. Despite the great success achieved, further extending their potential, to a great extent, depends on the possibility to assemble these nanocarbon materials into macroscopic 3D architectures while preserving the intrinsic properties of individual building components.
The electrochemical electrodes used in energy devices or for other purposes are conventionally planar. Electrodes based on 3D porous nanocarbon structures can greatly improve the capacity and efficiency because of largely expanded working volume, multiplexed conduction network, 3D interfacing, or intercalation with other system components (e.g., electrolytes, reactants). However, it is non-trivial to assemble CNTs and graphene sheets into 3D architectures due to their small size as well as stacking or aggregation caused by strong hydrophobic and pi–pi interactions. In this article, we review the latest development on synthesis of macroporous CNT/graphene structures and their applications in energy devices.
Synthesis Approaches
The 3D porous CNT and graphene structures can be readily fabricated from CNT/graphene solvent dispersions via self-assembly or substrate-based deposition, which are cost-effective and easily scalable. On the other hand, chemical vapor deposition (CVD) is able to produce 3D porous CNT/graphene monoliths, with high quality and well-defined architectures. Some other approaches have also been recently developed.
3D CNT structures
Direct deposition of dispersed CNTs onto a 3D substrate is simple and effective to construct porous architectures. For example, sponge with continuous 3D surface and good mechanical flexibility can serve as a supporting substrate. CNT-sponge composites fabricated via dip-coating method are highly porous (98%, pore size 200–500 μm) with large specific surface area of ~104 m2 m−3 (Xie et al., ). The thin CNT coating layer provides the composite a conductance of ~1 S cm−1. Without use of any template, self-assembled CNT foam has been made by a low temperature chemical fusion method (Figure 1) (Liu et al., ). Meso-/macroporosity of the CNT foam can be tuned by the amount of ammonia carbonate, which acts as the pore former. The as-synthesized CNT foam can withstand a stress pressure as high as 1.39 MPa. Catalytic growth of CNT forests via CVD method is advantageous in well controlling the length, quality, and density of CNTs (Zheng et al., ; Zhan et al., ). Zhao et al. () sputtered Fe catalysts on the surface of Ni foam for the growth of 3D randomly entangled CNTs. Shan et al. () synthesized 3D sponge-like N-doped CNT architecture, employing the mixture of ferrocene, thiophene, and pyridine as CVD precursors. The N and S are proposed to synergistically promote the formation of “elbow” and “welded” junctions between CNTs. In addition, the diameter of N-doped multi-walled CNTs can be easily controlled by modulating thiophene concentration, which in turn influences the mechanical and electrical properties of N-doped MWCNT sponge.
Figure 1
3D graphene structures
Graphene hydrogels and aerogels
The hydrophilic edges and hydrophobic basal planes of graphene oxide (GO) render it to be amenable to solution-based processes (Sun et al.,
Figure 2

(A) Scheme of the substrate-assisted reduction and assembly of GO on active metal substrate and arbitrary conductive target supported by active metal. Adapted with permission from Hu et al. (
Figure 3

(A) SEM image and schematic growth process of porous graphene structure prepared by sugar-blowing method. Adapted with permission from Wang et al. (
CVD grown 3D graphene
As first demonstrated by Chen et al. (
3D CNT–graphene hybrids
CNT and graphene possess a plethora of different characteristics in structural and physicochemical properties. To enjoy the synergistic effects of these two graphitic allotropes, 3D CNT/graphene hybrid architectures have been prepared by hydrothermal treatment of CNT and graphene solution mixture (You et al.,
Figure 4

Schematic illustrations of the fabricated 3D MnO2–CNT– graphene–Ni hybrids. Adapted with permission from Zhu et al. (
Functionalization
The 3D nanocarbon structures can be functionalized with biomolecules, polymers, or other functional nanomaterials (e.g., precious metal nanoparticles and nanostructured metal oxides) to attain improved or new functionalities (Georgakilas et al.,
Applications
Fuel cells
The 3D CNT/graphene structures have been employed as the electrochemical electrodes for fuel cells that convert chemical energy into electricity (Maiyalagan et al.,
Figure 5

(A) Illustration of the synthesis of the 3D Pt/graphene– carbon nitride catalyst and its electrochemical performance in direct methanol fuel cell. Adapted with permission from Huang et al. (
Biofuel cells
Biofuel cells share the same design with traditional fuel cell while replacing anode catalyst with biological components (enzymes or microorganisms), which are able to harvest biochemical energy into electricity. One major problem of enzymatic biofuel cell is the poor electron transfer from the buried catalytic centers of the enzyme molecules. To tackle this issue, Prasad et al. (
Supercapacitors
The 3D CNT/graphene architectures, with low level aggregation and agglomeration of individual CNTs of graphene sheets, are able to provide large electric double-layer capacitance (EDLC) owing to large surface area. In addition, they permit high loading of electrochemically active nanomaterials to gain high electrochemical pseudocapacitance. The 3D carbon nanocup-CNT structures have been synthesized on anodized aluminum oxide for EDLC based supercapacitors (Hahm et al.,
Jiang et al. (
Figure 6

(A) Schematic of the pseudocapacitor using CNT forests functionalized with oxidized nickel nanoparticles as the electrode and its cyclic voltammetry curves in 0.1 M KOH at scan rates of 100 mV s−1. Adapted with permission from Jiang et al. (
Lithium ion batteries
The 3D porous graphene/CNT architectures are also attractive for lithium ion batter (LIB), which can improve Li ion diffusion and tolerance to mechanical stress induced by ion deintercalation process. Ruoff group first applied CVD-grown 3D graphene for LIB cathode (Ji et al.,
Conclusion and Perspectives
In summary, electrochemical electrodes based on 3D nanocarbon structures, as compared with conventional planar electrodes, can greatly enhance the capacity, efficiency, or stability for the energy storage and conversion devices. Although this article focuses on energy devices, electrochemical electrodes based on 3D architecture of CNTs or graphene or their hybrid are also instrumental to other applications. For example, Dong et al. (
Statements
Acknowledgments
We thank the support from the Agency for Science, Technology and Research (A*STAR) under a SERC Grant (102 170 0142) and Ministry of Education of Singapore under an AcRF Tier 2 grant (MOE2011-T2-2-010).
Conflict of interest
The authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.
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Summary
Keywords
carbon nanotube, graphene, three-dimensional architecture, energy storage, energy conversion
Citation
Wang X, Sun G and Chen P (2014) Three-Dimensional Porous Architectures of Carbon Nanotubes and Graphene Sheets for Energy Applications. Front. Energy Res. 2:33. doi: 10.3389/fenrg.2014.00033
Received
15 July 2014
Accepted
04 August 2014
Published
20 August 2014
Volume
2 - 2014
Edited by
Lain-Jong Li, Academia Sinica, Taiwan
Reviewed by
Yumeng Shi, Singapore University of Technology and Design, Singapore; Yi-Hsien Lee, National Tsing-Hua University, Taiwan
Copyright
© 2014 Wang, Sun and Chen.
This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
*Correspondence: Peng Chen, Division of Bioengineering, School of Chemical and Biomedical Engineering, Nanyang Technological University, 70 Nanyang Drive 637457, Singapore e-mail: chenpeng@ntu.edu.sg
This article was submitted to Nanoenergy Technologies and Materials, a section of the journal Frontiers in Energy Research.
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