Millisecond tension-annealing for enhancing carbon nanotube fibers

Mechanically strong carbon nanotube (CNT) fibers have increasingly become the focus of the present research in the fiber industry. However, the weak or even a lack of interconnections between adjacent CNTs induces much inter-tube slippages during fiber failure, and thus results in their low mechanical strength. Moreover, achieving fast cross-linking between neighbouring CNTs on a large scale to prevent the failure by slip is still a big challenge. Herein we report an ultrafast and continuous tension-annealing process to achieve the considerably improved tube alignment and strong covalent cross-linking of neighbouring CNTs in milliseconds, resulting in great improvement of the fiber performance. The CNT fibers were heated to high temperature (∼2450 °C) by Joule heating under the applied tension and subsequently annealed for just 12 ms. Due to the rapid electromechanical response of the fibers, instant nanotube rearrangements coupled by the formation of cross-links robustly bonding the adjacent CNTs occurred at power-on, which could be attributed to the considerable increases of strength and modulus by factors of 2.9 (up to 3.2 GPa) and 4.8 (up to 123 GPa), respectively. The resultant fibers showed high specific strength (2.2 N per tex), comparable with that of PAN-based carbon fibers, and high specific electrical conductivity higher than that of PAN-based carbon fibers. Moreover, the obtained strongly crosslinked and highly dense structures also endowed the fibers with the significantly improved thermal stability under a high-temperature oxidation atmosphere. Moreover, a continuous tension-annealing process was designed to achieve the large scale production of high performance fibers with the average strength of 2.2 GPa. The high-toughness, lightweight and continuous features together with their outstanding mechanical and electrical properties would certainly boost the large-scale applications of CNT fibers.