Selective chemical doping of carbon nanotube conductors to reduce contact resistance with copper in ultrasonic welds

Abstract

Electrochemical devices such as batteries, fuel cells, and capacitors employing a carbon nanotube (CNT) electrode can be improved by lowering the contact resistance between CNTs and metallic contacts. The current work investigates two simultaneous strategies to enhance the contact by using chemical doping of CNTs with potassium tetrabromoaurate (KAuBr4) and ultrasonic welding to a metal foil. The specific contact resistivity was measured using the transfer length method (TLM) to evaluate CNT test structures having ultrasonically welded Cu contacts with and without KAuBr4 doping. Purified CNT-Cu samples had a specific contact resistivity of 5.4 mΩ cm2, whereas the KAuBr4 doped CNT-Cu samples were 2.2 mΩ cm2. Confirmation of selective doping to the weld region was made using measured differences in the emissivity of purified and KAuBr4 doped CNTs, which were 0.84 and 0.56, respectively. The lower contact resistance from KAuBr4 doped CNT-Cu ultrasonic welds also reduced the extent of Joule heating beyond the contact region when applying increasing current to failure in a 2-terminal test structure. The benefit of selectively doped CNT-Cu welds was demonstrated across rectangular ribbon and electrode form factors up to an area of 6 cm × 8 cm (typical of electrochemical pouch-cell current collectors). Each form factor showed a 1.5× reduction in peak temperature when selective doping of the CNTs was performed prior to ultrasonic welding of the Cu contact. Thus, the combination of selective doping and ultrasonic welding demonstrates a viable method to fabricate low electrical resistance between CNT electrodes and metallic contacts for electrochemical devices.