High-Strength Carbon Nanotube Fibers from Purity Control by Atomized Catalytic Pyrolysis and Alignment Improvement by Continuous Large Prestraining

Transferring the high strength of individual carbon nanotubes (CNTs) to macroscopic fibers is still a major technical challenge. In this study, CNT fibers are wound from a hollow cylindrical assembly. In particular, atomized catalytic pyrolysis is utilized to produce the fiber and control its purity. The pristine fiber is then continuously prestrained to have a highly aligned structure for subsequent full densification. Experimental measurements show that the final fiber possesses a high tensile strength (8.0 GPa), specific strength (5.54 N tex-1 (tex: the weight (g) of a fiber of 1 km long)), Young's modulus (350 GPa), and elongation at break (4%). Such an excellent combination is superior to that of any other existing fiber and attributed to the efficient stress transfer among the highly aligned and packed CNTs. Our study provides a new strategy involving atomized catalysis for developing superstrong CNT assemblies such as fibers and films for practical applications.

Expanded Carbon Nanotube Fiber at the Liquid-Air Interface for High-Performance Fiber-Based Supercapacitors and Electrochemical Sensors

Carbon nanotube fibers (CNTFs) are widely utilized in flexible and wearable electronics due to their outstanding electrical and mechanical properties. However, the spinning process of CNTFs has limited the CNTs from exposure, leading to an ultralow usage efficiency of individual CNTs. Here, we propose an electrochemical expansion strategy of a single CNTF at the liquid-air interface, forming a macroscopic spindle-shaped CNTF (SS-CNTF) with an enlarged volume of up to 5000-fold upon the spindle. The obtained spindle-shaped structure endows CNTF with a high specific surface area together with excellent conductivity and good mechanical properties. Therefore, the SS-CNTF-based devices exhibit outstanding performances both in energy storage (electrical double-layer supercapacitor, energy density: 11.22 Wh kg-1, power density: 203.9 kW kg-1) and electrochemical sensing (ascorbic acid: 1.26 μA μM-1 cm-2; dopamine: 103.91 μA μM-1 cm-2; uric acid: 11.53 μA μM-1 cm-2). The novel architecture of SS-CNTF prepared by one-step electrochemical expansion at the liquid-air interface enabled its high performance in multiple applications, providing new insight into the development of CNTF-based devices.

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.

Fabrication of high-performance carbon nanotube/copper composite fibers by interface thiol-modification

Carbon nanotube (CNT)/copper (Cu) composite fibers are placed great expectations as the next generation of light-weight, conductive wires. However, the electrical and mechanical performances still need to be enhanced. Herein, we demonstrate a strategy that is electrodeposition Cu on thiolated CNT fibers to solve the grand challenge which is enhancing the performance of CNT/Cu composite fibers. Thiol groups are introduced to the surface of the CNT fibers through a controllable O₂plasma carboxylation process and amide reaction. Compared with CNT/Cu composite fibers, there are 82.7% and 29.6% improvements in electrical conductivity and tensile strength of interface thiol-modification composite fibers. The enhancement mechanism is also explored that thiolated CNT fibers could make strong interactions between Cu and CNT, enhancing the electrical and mechanical performance of CNT/Cu composites. This work proposes a convenient, heat-treatment-free strategy for high-performance CNT/Cu composite fibers, which can be manufactured for large-scale production and applied to next-generation conductive wires.

Washable, Sewable, All-Carbon Electrodes and Signal Wires for Electronic Clothing

Smart wearable electronic accessories (e.g., watches) have found wide adoption; conversely, progress in electronic textiles has been slow due to the difficulty of embedding rigid electronic materials into flexible fabrics. Electronic clothing requires fibers that are conductive, robust, biocompatible, and can be produced on a large scale. Here, we create sewable electrodes and signal transmission wires from neat carbon nanotube threads (CNTT). These threads are soft like standard sewing thread, but they have metal-level conductivity and low interfacial impedance with skin. Electrocardiograms (EKGs) obtained by CNTT electrodes were comparable (P > 0.05) to signals obtained with commercial electrodes. CNTT can also be used as transmission wires to carry signals to other parts of a garment. Finally, the textiles can be machine-washed and stretched repeatedly without signal degradation. These results demonstrate promise for textile sensors and electronic fabric with the feel of standard clothing that can be incorporated with traditional clothing manufacturing techniques.

Carbon Nanotube Fibers Decorated with MnO2 for Wire-Shaped Supercapacitor

Fibers made from CNTs (CNT fibers) have the potential to form high-strength, lightweight materials with superior electrical conductivity. CNT fibers have attracted great attention in relation to various applications, in particular as conductive electrodes in energy applications, such as capacitors, lithium-ion batteries, and solar cells. Among these, wire-shaped supercapacitors demonstrate various advantages for use in lightweight and wearable electronics. However, making electrodes with uniform structures and desirable electrochemical performances still remains a challenge. In this study, dry-spun CNT fibers from CNT carpets were homogeneously loaded with MnO₂ nanoflakes through the treatment of KMnO₄. These functionalized fibers were systematically characterized in terms of their morphology, surface and mechanical properties, and electrochemical performance. The resulting MnO₂-CNT fiber electrode showed high specific capacitance (231.3 F/g) in a Na₂SO₄ electrolyte, 23 times higher than the specific capacitance of the bare CNT fibers. The symmetric wire-shaped supercapacitor composed of CNT-MnO₂ fiber electrodes and a PVA/H₃PO₄ electrolyte possesses an energy density of 86 nWh/cm and good cycling performance. Combined with its light weight and high flexibility, this CNT-based wire-shaped supercapacitor shows promise for applications in flexible and wearable energy storage devices.

High-Performance Thermoelectric Fabric Based on a Stitched Carbon Nanotube Fiber

With the continuous development of flexible and wearable thermoelectric generators (TEGs), high-performance materials and their integration into convenient wearable devices have to be considered. Herein, we have demonstrated highly aligned wet-spun carbon nanotube (CNT) fibers by optimizing the liquid crystalline (LC) phase via hydrochloric acid purification. The liquid crystalline phase facilitates better alignment of CNTs during fiber extrusion, resulting in the high power factor of 2619 μW m^-1 K^-2, which surpasses those of the dry-spun CNT yarns. A flexible all-carbon TEG was fabricated by stitching a single CNT fiber and doping selected segments into n-type by simple injection doping. The flexible TEG shows the maximum output power densities of 1.9 mW g^-1 and 10.3 mW m^-2 at ΔT = 30 K. Furthermore, the flexible TEG was developed into a prototype watch-strap TEG, demonstrating easy wearability and direct harvesting of body heat into electrical energy. Combining high-performance materials with scalable fabrication methods ensures the great potential for flexible/or wearable TEGs to be utilized as future power-conversion devices.

Super-Strong Carbon Nanotube Fibers Achieved by Engineering Gas Flow and Postsynthesis Treatment

Carbon nanotube fibers (CNTFs) are directly spun from a floating-catalyst chemical vapor deposition apparatus using gas-phase carbon and an iron nanocatalyst. The essential synthesis and post-treatment factors that affect the strength of CNTFs are investigated to obtain CNTFs with greater strength than those of any previously reported high-performance fibers. The key factors optimized included the degree of rotational flow inside the reactor, the ratio of the starting materials, and the postsynthesis treatment conditions. The formation of rotational gas flow inside the reactor was confirmed by computational fluid dynamics simulations, and the feed ratio of the starting materials was optimized through response surface methodology. In addition, a reproducible and highly efficient postsynthesis treatment method was established. Pristine CNTFs with a high specific strength (SS) (average 2.2 N/tex, max. 2.3 N/tex) were synthesized through decreased rotational flow and optimization of the CNTF synthesis conditions. To improve the SS of the CNTFs further, we adopted an acid wet-stretching method that included washing and heat treatment. This drastically increased the SS of the CNTFs (average 5.5 N/tex, max. 6.4 N/tex) because of the decrease in the volume of the pores between the CNT bundles.

Dynamic Liquid Membrane Electrochemical Modification of Carbon Nanotube Fiber for Electrochemical Microfabrication

Carbon nanotube fibers (CNFs) are a promising material for use as lightweight, high-strength, electrically conducting tool cathodes in wire electrochemical micromachining (WECMM) in which a high-performance tool cathode is crucial for optimal processing performance. However, the outstanding advantages of pristine CNFs, such as fiber strength, electrical conductivity, and hydrophilic surface, have so far remained underutilized as tool cathodes in WECMM. Herein, electrochemical modification using a dynamic liquid membrane is proposed as an effective online method for functionalizing CNFs prior to WECMM. The proposed method not only improves the assembly accuracy and efficiency but also avoids unnecessary damage to the modified CNF during installation. The introduced functional groups (-OH and -COOH) effectively improved the electrical conductivity and hydrophilicity of CNFs. The influences of H₂O₂ concentration, applied voltage, and anodization time on the surface modification process were examined experimentally. The use of a pulsed voltage was further proposed to prevent the loss of fiber strength due to over-anodization. Finally, the use of modified CNF electrodes with good surface morphology, strength, and conductivity in WECMM was demonstrated to afford superior machining stability, efficiency, and accuracy as well as improved surface quality compared with the conventional tool cathodes.

Enhanced Electrical and Mechanical Properties of Chemically Cross-Linked Carbon-Nanotube-Based Fibers and Their Application in High-Performance Supercapacitors

The electrical conductivity and mechanical strength of fibers constructed from single-walled carbon nanotubes (CNTs) are usually limited by the weak interactions between individual CNTs. In this work, we report a significant enhancement of both of these properties through chemical cross-linking of individual CNTs. The CNT fibers are made by wet-spinning a CNT solution that contains 1,3,5-tris(2'-bromophenyl)benzene (2TBB) molecules as the cross-linking agent, and the cross-linking is subsequently driven by Joule heating. Cross-linking with 2TBB increases the conductivity of the CNT fibers by a factor of ∼100 and increases the tensile strength on average by 47%; in contrast, the tensile strength of CNT fibers fabricated without 2TBB decreases after the same Joule heating process. Symmetrical supercapacitors made from the 2TBB-treated CNT fibers exhibit a remarkably high volumetric energy density of ∼4.5 mWh cm^-3 and a power density of ∼1.3 W cm^-3.

Ultrastrong and Stiff Carbon Nanotube/Aluminum-Copper Nanocomposite via Enhancing Friction between Carbon Nanotubes

Researchers have been aiming to replace copper with carbon nanotube/copper nanocomposites, which are lighter and exhibit better electrical, mechanical, and thermal properties. However, the strength is far below pure carbon nanotube assembly and even much lower than some copper-based alloys. This disadvantage hinders the extensive application of carbon nanotube/copper nanocomposites. In this study, the carbon nanotube/aluminum-copper nanocomposites with ultra-strength and stiffness were prepared. The strength and elasticity modulus of composite reached as high as 6.6 and 500 GPa, respectively, while a high conductivity of 1.8 × 10⁷ S/m was maintained. This can be attributed to the diffusion of Cu and Al atoms into the carbon nanotube fiber, which enhances friction between the carbon nanotubes by "pinning" and "bridging". This structure provides us with novel insights into the design of carbon nanotubes/metal nanocomposites with ultrahigh strength and conductivity.

Facile Synthesis of Na-Doped MnO2 Nanosheets on Carbon Nanotube Fibers for Ultrahigh-Energy-Density All-Solid-State Wearable Asymmetric Supercapacitors

Flexible fiber-shaped supercapacitors hold promising potential in the area of portable and wearable electronics. Unfortunately, their general application is hindered by the restricted energy densities due to low operating voltage and small specific surface area. Herein, an all-solid-state fiber-shaped asymmetric supercapacitor (FASC) possessing ultrahigh energy density is reported, in which the positive electrode was designed as Na-doped MnO₂ nanosheets on carbon nanotube fibers (CNTFs) and the negative electrode as MoS₂ nanosheet-coated CNTFs. Owing to the excellent properties of the designed electrodes, our FASCs exhibit a large operating potential window (0-2.2 V), a remarkable specific capacitance (265.4 mF/cm²), as well as an ultrahigh energy density (178.4 μWh/cm²). Moreover, the devices are of outstanding mechanical flexibility.

Significantly Increased Solubility of Carbon Nanotubes in Superacid by Oxidation and Their Assembly into High-Performance Fibers

This study demonstrates that small amount of oxygen incorporated into carbon nanotubes (CNTs) during the purification process greatly increases their solubility in chlorosulfonic acid (CSA). Using as-purchased and unpurified CNT powders, the optimal purification process is established to significantly increase the solubility of CNTs in CSA, and spin CNT fibers with high mechanical strength (0.84 N tex^-1 ) and electrical conductivity (1.4 MS m^-1 ) from the CNT liquid crystal dope with high concentration of CNTs in CSA. The knowledge obtained here may guide development of a way to dissolve extremely long CNTs at high concentration and thereby to enable production of CNT fibers with ultimate properties.

Alignment of Carbon Nanotubes in Carbon Nanotube Fibers Through Nanoparticles: A Route for Controlling Mechanical and Electrical Properties

This is the first study that describes how semiconducting ZnO can act as an alignment agent in carbon nanotubes (CNTs) fibers. Because of the alignment of CNTs through the ZnO nanoparticles linking groups, the CNTs inside the fibers were equally distributed by the attraction of bonding forces into sheetlike bunches, such that any applied mechanical breaking load was equally distributed to each CNT inside the fiber, making them mechanically robust against breaking loads. Although semiconductive ZnO nanoparticles were used here, the electrical conductivity of the aligned CNT fiber was comparable to bare CNT fibers, suggesting that the total electron movement through the CNTs inside the aligned CNT fiber is not disrupted by the insulating behavior of ZnO nanoparticles. A high degree of control over the electrical conductivity was also demonstrated by the ZnO nanoparticles, working as electron movement bridges between CNTs in the longitudinal and crosswise directions. Well-organized surface interface chemistry was also observed, which supports the notion of CNT alignment inside the fibers. This research represents a new area of surface interface chemistry for interfacially linked CNTs and ZnO nanomaterials with improved mechanical properties and electrical conductivity within aligned CNT fibers.

Toughness of carbon nanotubes conforms to classic fracture mechanics

Defects in crystalline structure are commonly believed to degrade the ideal strength of carbon nanotubes. However, the fracture mechanisms induced by such defects, as well as the validity of solid mechanics theories at the nanoscale, are still under debate. We show that the fracture toughness of single-walled nanotubes (SWNTs) conforms to the classic theory of fracture mechanics, even for the smallest possible vacancy defect (~2 Å). By simulating tension of SWNTs containing common types of defects, we demonstrate how stress concentration at the defect boundary leads to brittle (unstable) fracturing at a relatively low strain, degrading the ideal strength of SWNTs by up to 60%. We find that, owing to the SWNT's truss-like structure, defects at this scale are not sharp and stress concentrations are finite and low. Moreover, stress concentration, a geometric property at the macroscale, is interrelated with the SWNT fracture toughness, a material property. The resulting SWNT fracture toughness is 2.7 MPa m(0.5), typical of moderately brittle materials and applicable also to graphene.

Mechanical Strength Improvements of Carbon Nanotube Threads through Epoxy Cross-Linking

Individual Carbon Nanotubes (CNTs) have a great mechanical strength that needs to be transferred into macroscopic fiber assemblies. One approach to improve the mechanical strength of the CNT assemblies is by creating covalent bonding among their individual CNT building blocks. Chemical cross-linking of multiwall CNTs (MWCNTs) within the fiber has significantly improved the strength of MWCNT thread. Results reported in this work show that the cross-linked thread had a tensile strength six times greater than the strength of its control counterpart, a pristine MWCNT thread (1192 MPa and 194 MPa, respectively). Additionally, electrical conductivity changes were observed, revealing 2123.40 S·cm^-1 for cross-linked thread, and 3984.26 S·cm^-1 for pristine CNT thread. Characterization suggests that the obtained high tensile strength is due to the cross-linking reaction of amine groups from ethylenediamine plasma-functionalized CNT with the epoxy groups of the cross-linking agent, 4,4-methylenebis(N,N-diglycidylaniline).