The authors report a simple method for providing a polymer support structure for carbon nanotube ͑CNT͒ arrays for device applications. This method has a twofold effect: firstly it secures the nanotubes to the substrate and secondly it significantly decreases the threshold field for field emission from 26.2 to 9.7 V / m. This method ensures that the main body and tips of the CNTs are polymer-free and therefore can also be applied to CNT sensor array device fabrication. © 2006 American Institute of Physics. ͓DOI: 10.1063/1.2345615͔ Aligned carbon nanotube ͑CNT͒ arrays 1,2 are attracting increased interest for sensing applications and are currently studied as platforms for a variety of sensor devices 3-5 and field emission ͑FE͒ sources in flat screen displays.6,7 An underlying drawback for CNT arrays being used as sensing platforms is the fact that the nanotubes are weakly bound to the silicon substrate and are susceptible to facile detachment ͓Fig. 1͑a͒: effect from scratching͔, which reduces performance and lifetime, when incorporated in sensor and display technologies. Recently, there has been much investigation into the possible toxicological effects of carbon nanotubes with biological systems. 8,9 In the case of CNT electrophysiological sensors, 10 nanotube detachment from the substrate becomes an important issue.There are several additional issues to be tackled if CNTs are to become viable FE materials, such as improvement of turn on fields, mechanical stability, and the robustness of the substrates. Degradation of CNT arrays during FE occurs mainly due to mechanical failure at the tube-substrate contact and resistive heating.11 Plasma post-treatment with O 2 , 12 CF 4 , 13 Ar, 14 and H 2 ͑Ref. 15͒ has been used to alter the FE properties of CNT arrays by removing surface amorphous carbon impurities, 16,17 introducing defects, 15 and by modifying the work function of the surface of the CNTs.12 Previous work has shown that O 2 impurities etch the base of the CNTs during FE characterization due to large contact resistances between the substrate and CNTs, resulting in an increase in threshold field.
18Our previous work has revealed that polystyrene ͑PS͒-multiwall carbon nanotube ͑MWNT͒ composite films exhibit excellent FE properties ͑low threshold fields: 1.6 V / m͒ from the fracture surface at relatively low CNT concentrations ͑ca. 12 wt. %͒. 19,20 Further investigation of the fracture surface by scanning electron microscopy ͑SEM͒ shows that after the MWNTs have been pulled out of the PS matrix, there remains polymer attached to the nanotube surface, indicating good adhesion between the tubes and polymer ͓Fig. 1͑b͔͒.We have developed a facile method for the fabrication of a thin PS support, which holds the tubes securely to the substrate surface while ensuring that the nanotubes are free of polymer and available for FE and chemical/biological functionalization. We demonstrate that the FE properties are noticeably enhanced after the polymer layer has been fabricated due to the oxygen plasma treatment step. Thres...