Ultrastrong Graphene-Copper Core-Shell Wires for High-Performance Electrical Cables

Copper-Graphene Composite (CGC) Conductors: Synthesis, Microstructure, and Electrical Performance

Improving the electrical performance of copper, the most widely used electrical conductor in the world is of vital importance to the progress of key technologies, including electric vehicles, portable devices, renewable energy, and power grids. Copper-graphene composite (CGC) stands out as the most promising candidate for high-performance electrical conductor applications. This can be attributed to the superior properties of graphene fillers embedded in CGC, including excellent electrical and thermal conductivity, corrosion resistance, and high mechanical strength. This review highlights the recent progress of CGC conductors, including their fabrication processes, electrical performances, mechanisms of copper-graphene interplay, and potential applications.

Polypyrrole-coated copper@graphene core-shell nanoparticles for supercapacitor application

The performance of supercapacitors strongly depends on the electrochemical characterizations of electrode materials. Herein, a composite material consisted of polypyrrole (PPy) and multilayer graphene-wrapped copper nanoparticles (PPy/MLG-Cu NPs) is fabricated on a flexible carbon cloth (CC) substrate via two-step synthesis process for supercapacitor application. Where, MLG-Cu NPs are prepared on CC by one-step chemical vapor deposition synthesis approach; thereafter, the PPy is further deposited on the MLG-Cu NPs/CC via electropolymerization. The related material characterizations of PPy/MLG-Cu NPs are well investigated by scanning electron microscopic, high resolution transmission electron microscopy, Raman spectrometer and x-ray photoelectron spectroscopy; the electrochemical behaviors of the pertinent electrodes are studied by cyclic voltammogram, galvanostatic charge/discharge and electrochemical impedance spectroscopy measurements. The flexible electrode with PPy/MLG-Cu NPs composites exhibits the best specific capacitance of 845.38 F g^-1at 1 A g^-1, which is much higher than those of electrodes with PPy (214.30 F g^-1), MLG-Cu NPs (6.34 F g^-1), multilayer graphene hollow balls (MLGHBs; 52.72 F g^-1), and PPy/MLGHBs (237.84 F g^-1). Finally, a supercapacitor system consisted of four PPy/MLG-Cu NPs/CC electrodes can efficiently power various light-emitting diodes (i.e. red, yellow, green and blue lighs), demonstrating the practical application of PPy/MLG-Cu NPs/CC electrode.

Ultrastrong Carbon Nanotubes-Copper Core-Shell Wires with Enhanced Electrical and Thermal Conductivities as High-Performance Power Transmission Cables

Demands for high-performance electrical power transmission cables continue to rise, especially for offshore power transmission, electric vehicles, portable electronics, and deployable military applications. Carbon nanotubes (CNTs)-Copper (Cu) core-shell wire is regarded as one of the best candidate material systems for transmitting electricity and thermal energy. In this study, a facile and robust approach was developed to enhance the CNT-Cu interfacial interactions. This approach consists of a substrate-enhanced electroless deposition step for Cu pre-seeding and thiol functionalization. Benefiting from the thiol-activated CNT surface and Cu seed deposit, the CNTs-Cu core-shell wire forms a densely packed Cu shell with a void-free CNT-Cu interface. Consequently, the CNTs-Cu core-shell wire possesses (1) superior specific strength (eightfold stronger), (2) 30% higher specific conductivity, (3) 120% higher specific ampacity, and (4) an impressive 110% higher thermal conductivity compared with pure Cu wires. Moreover, this composite wire still maintains its structural integrity and electrical properties over 600 cycles of the fatigue bending test, rendering this system an excellent candidate for high-performance electrical cable and conductor applications.

Structural Design and Fabrication of Multifunctional Nanocarbon Materials for Extreme Environmental Applications

Extreme environments represent numerous harsh environmental conditions, such as temperature, pressure, corrosion, and radiation. The tolerance of applications in extreme environments exemplifies significant challenges to both materials and their structures. Given the superior mechanical strength, electrical conductivity, thermal stability, and chemical stability of nanocarbon materials, such as carbon nanotubes (CNTs) and graphene, they are widely investigated as base materials for extreme environmental applications and have shown numerous breakthroughs in the fields of wide-temperature structural-material construction, low-temperature energy storage, underwater sensing, and electronics operated at high temperatures. Here, the critical aspects of structural design and fabrication of nanocarbon materials for extreme environments are reviewed, including a description of the underlying mechanism supporting the performance of nanocarbon materials against extreme environments, the principles of structural design of nanocarbon materials for the optimization of extreme environmental performances, and the fabrication processes developed for the realization of specific extreme environmental applications. Finally, perspectives on how CNTs and graphene can further contribute to the development of extreme environmental applications are presented.

Hybrid 1D/2D nanocarbon-based conducting polymer nanocomposites for high-performance wearable electrodes

A low interfacial contact resistance is a challenge in polymer nanocomposites based on conductive nanomaterials for high-performance wearable electrode applications. Herein, a polydimethylsiloxane (PDMS)-based flexible nanocomposite incorporating high-conductivity 1D single-walled carbon nanotubes (SWCNTs) and 2D reduced graphene oxide (r-GO) was developed for high-performance electrocardiogram (ECG) wearable electrodes. A PDMS-SWCNT (P-SW; type I) nanocomposite containing only SWCNTs (2 wt%), exhibited rough and non-uniform surface morphology owing to the strong bundling effect of as-grown SWCNTs and randomly entangled aggregate structures and because of inefficient vacuum degassing (i.e., R _P-SW = 1871 Ω). In contrast, owing to the hybrid structure of the SWCNTs (1 wt%) and r-GO (1 wt%), the PDMS-SWCNTs/r-GO (P-SW/r-GO; type II) nanocomposite exhibited uniform surface characteristics and low contact resistance (i.e., R _P-SW/r-GO = 63 Ω) through the formation of hybrid and long conducting pathways. The optimized nanocomposite (P-SW/r-GO/f; type III) possessed a fabric-assisted structure that enabled tunable and efficient vacuum degassing and curing conditions. Additionally, a long and wide conducting pathway was formed through more uniform and dense interconnected structures, and the contact resistance was drastically reduced (i.e., R _P-SW/r-GO/f = 15 Ω). The performance of the electrodes fabricated using the optimized nanocomposites was the same or higher than that of commercial Ag/AgCl gel electrodes during real-time measurement for ECG Bluetooth monitoring. The developed high-performance hybrid conducting polymer electrodes are expected to contribute significantly to the expansion of the application scope of wearable electronic devices and wireless personal health monitoring systems.

Freestanding Graphene Fabric Film for Flexible Infrared Camouflage

Graphene films, fabricated by chemical vapor deposition (CVD) method, have exhibited superiorities in high crystallinity, thickness controllability, and large-scale uniformity. However, most synthesized graphene films are substrate-dependent, and usually fragile for practical application. Herein, a freestanding graphene film is prepared based on the CVD route. By using the etchable fabric substrate, a large-scale papyraceous freestanding graphene fabric film (FS-GFF) is obtained. The electrical conductivity of FS-GFF can be modulated from 50 to 2800 Ω sq^-1 by tailoring the graphene layer thickness. Moreover, the FS-GFF can be further attached to various shaped objects by a simple rewetting manipulation with negligible changes of electric conductivity. Based on the advanced fabric structure, excellent electrical property, and high infrared emissivity, the FS-GFF is thus assembled into a flexible device with tunable infrared emissivity, which can achieve the adaptive camouflage ability in complicated backgrounds. This work provides an infusive insight into the fabrication of large-scale freestanding graphene fabric films, while promoting the exploration on the flexible infrared camouflage textiles.

An Axially Continuous Graphene-Copper Wire for High-Power Transmission: Thermoelectrical Characterization and Mechanisms

The demand for high-power electrical transmission continues to increase with technical advances in electric vehicles, unmanned drones, portable devices, and deployable military applications. In this study, significantly enhanced electrical properties (i.e., a 450% increase in the current density breakdown limit) are demonstrated by synthesizing axially continuous graphene layers on microscale-diameter wires. To elucidate the underlying mechanisms of the observed enhancements, the electrical properties of pure copper wires and axially continuous graphene-copper (ACGC) wires with three different diameters are characterized while controlling the experimental conditions, including ambient temperature, gases, and pressure. The study reveals that the main mechanism that allows the application of extremely large current densities (>400 000 A cm^-2 ) through the ACGC wires is threefold: the continuous graphene layers considerably improve: 1) surface heat dissipation (224% higher), 2) electrical conductivity (41% higher), and 3) thermal stability (41.2% lower resistivity after thermal cycles up to 450 °C), compared with pure copper wires. In addition, it is observed, through the use of high-speed camera images, that the ACGC wires exhibit very different failure behavior near the current density limit, compared with the pure copper wires.

The Strength and Delamination of Graphene/Cu Composites with Different Cu Thicknesses

This study analyzed the mechanical and fracture behavior of graphene/copper (Cu) composites with different Cu thicknesses by using molecular dynamics (MD) and representative volume element (RVE) analysis. Three graphene/Cu composite analytical models were classified as 4.8, 9.8, and 14.3 nm according to Cu thicknesses. Using MD analysis, zigzag-, armchair-, and z (thickness)-direction tensile analyses were performed for each model to analyze the effect of Cu thickness variation on graphene/Cu composite strength and delamination fracture. In the RVE analysis, the mechanical characteristics of the interface between graphene and Cu were evaluated by setting the volume fraction to 1.39, 2.04, and 4.16% of the graphene/Cu composite model, classified according to the Cu thickness. From their obtained results, whether the graphene bond is maintained has the greatest effect on the strength of graphene/Cu composites, regardless of the Cu thickness. Additionally, graphene/Cu composites are more vulnerable to armchair direction tensile forces with fracture strengths of 14.7, 8.9, and 8.2 GPa depending on the Cu thickness. The results of this study will contribute to the development of guidelines and performance evaluation standards for graphene/Cu composites.

Scallion-Inspired Graphene Scaffold Enabled High Rate Lithium Metal Battery

Graphene-based one-dimensional macroscopic assemblies (GBOMAs) have attracted great attention and extensive efforts have been devoted to enabling great progress. However, their applications are still restricted to less functionalized electronics, and the superior potentials remain scarce. Herein, inspired by natural scallion structure, a novel strategy was introduced to effectively improve battery performances through the mesoscale scallion-like wrapping of graphene. The obtained RGO/Ag-Li anodes demonstrated an ultralow overpotential of ∼11.3 mV for 1800 h at 1 mA cm^-2 in carbonate electrolytes, which is superior to those of the most previous reports. Besides, this strategy can also be further expanded to the high mass loading of various cathode nanomaterials, and the resulting RGO/LiFePO₄ cathodes exhibited remarkable rate performance and cycle stability. This work opens a new avenue to explore and broaden the applications of GBOMAs as scaffolds in fabricating full lithium batteries via maximizing their advantages derived from the unique structure and properties.

Multifunctional reduced graphene oxide-CVD graphene core-shell fibers

The insufficient electrical conductivity and mechanical stretchability of conventional graphene fibers based on reduced graphene oxide liquid crystals (rGO-LCs) has limited their applications to numerous textile devices. Here, we report a simple method to fabricate multifunctional fibers with mechanically strong rGO cores and highly conductive CVD graphene shells (rGO@Gr fibers), which show an outstanding electrical conductivity as high as ∼137 S cm-1 and a failure strain value of 21%, which are believed to be the highest values among polymer-free graphene fibers. We also demonstrate the use of the rGO@Gr fibers for high power density supercapacitors with enhanced mechanical stability and durability, which would enable their practical applications in various smart wearable devices in the future.

Electroless Plating of Graphene Aerogel Fibers for Electrothermal and Electromagnetic Applications

Graphene aerogel fibers (GAFs) with low density, high specific surface area, and high porosity can be used as the host material to incorporate another component and thus form multifunctional fibers, which have potential applications in wearable devices, thermoregulating apparatus, sensors, and so forth. However, the intrinsically low electric conductivity of GAFs hampers them in the fields of electrothermal heating and electromagnetic interference (EMI) shielding. Herein, we report a new aerogel fiber composed by graphene sheets and nickel nanoparticles with low density (55-192 mg/cm³), high electric conductivity (0.8 × 10³ to 4.5 × 10⁴ S/m), and high specific surface area (49-105 m²/g). The graphene/Ni aerogel fibers (GNAFs) were synthesized initially from reduced graphene oxide hydrogel fibers followed by an electroless plating process. Further investigations have demonstrated that the resulting GNAFs possess excellent electrothermal property, faster electrothermal response, high mechanical and electrical stability as the electric wire, and excellent EMI shielding performance as the composite filler. The saturated temperature of GNAFs can reach 174 °C with an applied voltage of only 5 V, and the heating rate surpasses those of commercial Kanthal and Nichrome wires about 2.1 times and 2.6 times, respectively. The EMI shielding effectiveness of GNAFs is higher than 30 dB at the long bandwidth of 12.5-20 GHz. Specifically, it can shield more than 99.99% of the incident wave at the bandwidth of 15-20 GHz.

Electrical Conductivity Modeling of Graphene-based Conductor Materials

Graphene-based conductors such as films and fibers aim to transfer graphene's extraordinary properties to the macroscopic scale. They show great potential for large-scale applications, but there is a lack of theoretical models to describe their electrical characteristics. We present a network simulation method to model the electrical conductivity of graphene-based conductors. The method considers all of the relevant microscopic parameters such as graphene flake conductivity, interlayer conductivity, packing density, and flake size. To provide a mathematical framework, we derive an analytical expression, which reproduces the essential features of the network model. We also find good agreement with experimental data. Our results offer production guidelines and enable the systematic optimization of high-performance graphene-based conductor materials. A generalization of the model to any conductor based on two-dimensional materials is straightforward.