Carbon nanotube synthesis and spinning as macroscopic fibers assisted by the ceramic reactor tube.

Macroscopic fibers of carbon nanotubes (CNT) have emerged as an ideal architecture to exploit the exceptional properties of CNT building blocks in applications ranging from energy storage to reinforcement in structural composites. Controlled synthesis and scalability are amongst the most pressing challenges to further materialize the potential of CNT fibers. This work shows that under floating catalyst chemical vapor conditions in the direct spinning method, used both in research and industry, the ceramic reactor tube plays an unsuspected active role in CNT growth, leading for example to doubling of reaction yield when mullite (Al4+2xSi2-2xO10-x(x ≈ 0:4)) is used instead of alumina (Al2O3), but without affecting CNT morphology in terms of number of layers, purity or degree of graphitization. This behaviour is confirmed for different carbon sources and when growing either predominantly single-walled or multi-walled CNTs by adjusting promotor concentration. Analysis of large Si-based impurities occasionally found in CNT fiber fabric samples, attributed to reactor tube fragments that end up trapped in the porous fibers, indicate that the role of the reactor tube is in catalyzing the thermal decomposition of hydrocarbons, which subsequently react with floating Fe catalyst nanoparticles and produce extrusion of the CNTs and formation of an aerogel. Reactor gas analysis confirms that extensive thermal decomposition of the carbon source occurs in the absence of Fe catalyst particles, and that the concentration of different carbon species (e.g. carbon dioxide and ethylene) is sensitive to the reactor tube type. These finding open new avenues for controlled synthesis of CNT fibers by decoupling precursor decomposition from CNT extrusion at the catalyst particle.

Macroscopic fibres of CNTs as electrodes for multifunctional electric double layer capacitors: from quantum capacitance to device performance.

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.

Inherent predominance of high chiral angle metallic carbon nanotubes in continuous fibers grown from a molten catalyst.

We present evidence that high temperature CVD growth of SWNTs under conditions of continuous spinning of macroscopic fibers leads to an inherent predominance of high chiral angle CNTs, peaking at the armchair end. Raman, UV-vis-NIR absorption, and photoluminescence spectroscopy measurements show the prevalence of metallic SWNTs. The complete chiral angle distribution is obtained by electron diffraction of over 390 CNTs. It is biased towards high chiral angles and peaks at the armchair end (30°), in good agreement with the established atomistic models for SWNT growth from a liquid catalyst. Based on the Fe-C-S constituent binary and ternary phase diagrams, thermodynamic calculations of phase compositions from fast cooling and experimental evidence of a post-synthesis catalyst, the proposed thermodynamic path of the catalyst is to form a solid FCC Fe core and a liquid Fe-S shell. S in the outer liquid shell first stabilizes the edge of the nascent CNT, but once a graphitic wall forms it is rejected due to the high interfacial energy of the Fe-C-S alloy.