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Dry sonication process for preparation of hybrid structures based on graphene and carbon nanotubes usable for chemical sensors

The combination of graphene (G) and multi-walled carbon nanotubes (MWCNTs) creates three-dimensional hybrid structures particularly suitable as next-generation electrical interface materials. Nevertheless, efficient mixing of the nanopowders is challenging, unless previous disaggregation and eventual surface modification of both is reached. To avoid use of solvents and multistep purification process for synthesis of stable G/MWCNTs hybrids, herein, a novel dry method based on an air sonication process was used. Taking advantage from the vigorous turbulent currents generated by powerful ultrasonication in air that induces strong thermal convection or radiation to and from the particles, it simultaneously ensures disentanglement of the large MWCNT bundles and G exfoliation and their only mild surface modifications. By changing the ratio between MWCNTs and G, a range of hybrids was obtained, different in surface morphology and chemistry. These hybrids have shown great potential as sensing material for designing mass-based sensors for toxic gases and chemiresistor for vapors detection.