We report on the synthesis of kilometers of continuous macroscopic fibers made up of carbon nanotubes (CNT) of controlled number of layers, ranging from single-walled to multiwalled, tailored by the addition of sulfur as a catalyst promoter during chemical vapor deposition in the direct fiber spinning process. The progressive transition from single-walled through collapsed double-walled to multiwalled is clearly seen by an upshift in the 2D (G′) band and by other Raman spectra features. The increase in number of CNT layers and inner diameter results in a higher fiber macroscopic linear density and greater reaction yield (up to 9%). Through a combination of multiscale characterization techniques (X-ray photoelectron spectroscopy, organic elemental analysis, high-resolution transmission electron microscopy, thermogravimetric analysis, and synchrotron XRD) we establish the composition of the catalyst particles and position in the isothermal section of the C–Fe–S ternary diagram at 1400 °C. This helps explain the unusually low proportion of active catalyst particles in the direct spinning process (<0.1%) and the role of S in limiting C diffusion and resulting in catalyst particles not being in thermodynamic equilibrium with solid carbon, therefore producing graphitic edge growth instead of encapsulation. The increase in CNT layers is a consequence of particle coarsening and the ability of larger catalyst particles to accommodate more layers for the same composition.

We present a method to spin highly oriented continuous fibers of adjustable carbon nanotube (CNT) type, with mechanical properties in the high-performance range. By lowering the concentration of nanotubes in the gas phase, through either reduction of the precursor feed rate or increase in carrier gas flow rate, the density of entanglements is reduced and the CNT aerogel can thus be drawn (up to 18 draw ratio) and wound at fast rates (>50 m/min). This is achieved without affecting the synthesis process, as demonstrated by Raman spectroscopy, and implies that the parameters controlling composition in terms of CNT diameter and number of layers are decoupled from those fixing CNT orientation. Applying polymer fiber wet-spinning principles then, strong CNT fibers (1 GPa/SG) are produced under dilute conditions and high draw ratios, corresponding to highly aligned fibers (from wide- and small-angle X-ray scattering). This is demonstrated for fibers either made up of predominantly single-wall CNTs (SWCNTs) or predominantly multiwall CNTs (MWCNTs), which surprisingly have very similar tensile properties. Finally, we show that postspin densification has no substantial effect on either alignment or properties (mechanical and electrical). These results demonstrate a route to control CNT assembly and reinforce their potential as a high-performance fiber.

In this work we present a combined electrochemical and mechanical study of mesoporous electrodes based on CNT fibres in the context of electric double layer capacitors. We show that through control of the synthetic and assembly processes of the fibres, it is possible to obtain an active material that combines a surface area of 250 m(2) g(-1), high electrical conductivity (3.5 × 10(5) S m(-1)) and mechanical properties in the high-performance range including toughness (35 J g(-1)) comparable to that of aramid fibre (e.g. Kevlar). These properties are a consequence of the predominant orientation of the CNTs, observed by wide- and small-angle X-ray diffraction, and to the exceptionally long CNT length on the millimetre scale. Cyclic voltammetry measurements in a three-electrode configuration and using 1-butyl-3-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide (PYR14TFSI) ionic liquid electrolyte, show that the CNT fibres have a large quantum capacitance, evidenced by the near linear dependence of geometric capacitance (and conductivity) on potential bias. This reflects the low dimensionality of the CNT building blocks, which were purposely synthesised to have 1-5 layers and a high degree of graphitization. From the charge-discharge measurements of supercapacitor devices with symmetric CNT fibre electrodes we obtain power and energy densities as high as 58 kW kg(-1) and 14 Wh kg(-1), respectively. These record-high values for CNT fibre-based supercapacitors, are a consequence of the low equivalent series resistance due to the high conductivity of the fibres, the large contribution from quantum capacitance, and the wide stability window of the ionic liquid (3.5 V). Cycle life experiments demonstrate stable capacitance and energy retention over 10,000 cycles of charge-discharge at 3.5 V.

This work presents a scalable method to produce robust all-solid electric double layer capacitors (EDLCs), compatible with roll-to-roll processes and structural laminate composite fabrication. It consists in sandwiching and pressing an ionic liquid (IL) based polymer electrolyte membrane between two CNT fiber sheet electrodes at room temperature, and laminating with ordinary plastic film. This fabrication method is demonstrated by assembling large area devices of up to 100 cm 2 with electrodes fabricated in-house, as well as with commercial CNT fiber sheets. Free-standing flexible devices operating at 3.5 V exhibited 28 F g -1 of specific capacitance, 11.4 Wh kg -1 of energy density and 46 kW kg -1 of power density. These values are nearly identical to control samples with pure ionic liquid. The solid EDLC could be repeatedly bent and folded 180° without degradation of their properties, with a reversible 25% increase in energy density in the bent state. Devices produced using CNT

A comparative study on interfacial crystallization of isotactic polypropylene (iPP) surrounding macroscopic carbon nanotube and graphene fibers has been carried out in single fiber polymer composites by means of in situ polarized optical microscope, scanning electron microscope and X-ray diffraction. Ordered interfacial microstructures of iPP nucleate on both nanocarbon fibers in the form of a transcrystalline interphase. Nanotube fibers tend to promote negative birefringence transcrystals whereas graphene fibers induce positive birefringence transcrystals. The microstructures of transcrystals are strongly dependent on the thermal history and the double-layered transcrystals consisting of a negative inner layer and a positive outer layer occur under certain conditions. Transcrystallization kinetics has been studied and the Lauritzen-Hoffman theory of heterogeneous nucleation used to analyze the dynamic crystallization process. While the fold surface energy of iPP transcrystals surrounding both nanocarbon fibers shows little difference, the nanotube fiber promotes shorter induction time than the graphene fiber. Thermal resistance test demonstrates that the ordered interfacial microstructures possess higher melting temperature in the nanotube fiber composites than those in the graphene fiber composites. Under appropriate conditions, the-form transcrystals of iPP are observed. The amount of the-form iPP surrounding the nanotube fiber is much higher than that surrounding the graphene fiber. A theoretical model is proposed to interpret the difference between the nanotube and graphene fiber composites and the mechanisms behind its influence on interfacial crystallization.