Rapid synthesis of a BN/CNT composite particle via spray routes using ferrocene/ethanol as a catalyst/carbon source

Boron nitride (BN)/carbon nanotube (CNT) composite particles in submicrometer-sizes were successfully prepared using a spray pyrolysis method. Using an ultrasonic nebulizer, BN nanoparticles, ferrocene (as catalyst), and ethanol (as solvent and carbon source) were sprayed into a tubular furnace (fixed temperature of 800 °C) under an Argon flow of 1 L/min. Ethanol was used as a solvent as well as a carbon source because of its non-polluting nature, low cost, harmless byproducts (e.g. CO), and ease of handling. An aggregated BN particle with the growth of a multiwall-CNT (10 nm in thickness) on the surface could be produced. No BN phase changed because the process was completed in a matter of seconds. The present novel synthesis method could be broadly applied in the fabrication of various composite materials with the growth of CNT on the particle surface using a simple, fast and continuous process.