Carbon film produced from microwave-driven methane pyrolysis
Mehran Dadsetan, Kenneth G. Latham, Boran Kumral, Mohammad Fawaz Khan, Mia Scott, Tirthankar Mitra, Ali Naseri, Sama Manzoor, Erin R. Bobicki, Tobin Filleter, Maria‐Magdalena Titirici, Murray J. Thomson
Abstract
Methane pyrolysis is a widely used technique for producing hydrogen and valuable carbon materials. Among these materials are carbon films, which have a diverse range of properties that make them useful for various applications. This study focuses on synthesizing a new type of carbon film through a microwave-driven methane pyrolysis process. The resulting metallic-like carbon film deposits on a polished quartz substrate and detaches as it thickens. We conducted a thorough characterization of the film's properties, using different techniques to study its surface morphology and structural features. Our findings show that the carbon film has a smooth surface texture and a semi-graphitic internal structure, with 78% of the carbon atoms exhibiting sp2 bonding as revealed by X-ray photoelectron spectroscopy. X-ray diffraction analysis further confirms the presence of microcrystalline carbon fragments within the film. Additionally, conductivity measurements using a conductive-atomic force microscope demonstrate the carbon film's remarkable electrical conductivity, comparable to that of gold and silver metals. The electrochemical measurements indicate that the carbon film's high conductivity and free-standing nature make it a promising candidate for use as a direct active material in sodium-ion batteries. This is because the film does not require binders or conductive agents, which can improve battery performance.