High-purity and well-graphitized single-walled carbon nanotubes (SWCNTs) with excellent physiochemical properties are ideal building blocks for the assembly of various CNT macrostructures for a wide range of applications. We report the preparation of high-quality SWCNTs on a large scale using a floating catalyst chemical vapor deposition (FCCVD) method. Under the optimum conditions, the conversion rate of the carbon source to SWCNTs reached 28.8%, and 20.4% of the metal nanoparticles were active for SWCNT growth, which are 15% and ∼400 times higher than those previously reported for FCCVD synthesis, respectively. As a result, the prepared SWCNTs have a very low residual catalyst content of ∼1.9 wt % and a high rapid oxidation temperature of 717 °C. Using these high-quality SWCNTs, we spun macroscopic SWCNT fibers by a wet-spinning process. The resulting fibers had a high electrical conductivity of 6.67 MS/m, which is 32% higher than the best value previously reported for SWCNT fibers.

Carbon nanotube (CNT)/Cu core−shell fibers are a promising material for lightweight conductors due to their higher conductivity than pure CNT fibers and lower density than traditional Cu wires. However, the electrical properties of the hybrid fiber have been unsatisfactory, mainly because of the weak CNT−Cu interfacial interaction. Here we report the fabrication of a single-walled CNT (SWCNT)/Cu core−shell fiber that outperforms commercial Cu wires in terms of specific electrical conductivity and current carrying capacity. A dense and uniform Cu shell was coated on the surface of wet-spun SWCNT fibers using a combination of magnetron sputtering and electrochemical deposition. Our SWCNT/Cu core−shell fibers had an ultrahigh specific electrical conductivity of (1.01 ± 0.04) × 10 4 S m 2 kg −1 , 56% higher than Cu. Experimental and simulation results show that oxygen-containing functional groups on the surface of a wetspun SWCNT fiber interact with the sputtered Cu atoms to produce strong bonding. Our hybrid fiber preserved its integrity and conductivity well after more than 5000 bending cycles. Furthermore, the current carrying capacity of the coaxial fiber reached 3.14 × 10 5 A cm −2 , three times that of commercial Cu wires.

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