We study how intrinsic parameters of carbon nanotube (CNT) samples affect the properties of macroscopic CNT fibers with optimized structure. We measure CNT diameter, number of walls, aspect ratio, graphitic character, and purity (residual catalyst and non-CNT carbon) in samples from 19 suppliers; we process the highest quality CNT samples into aligned, densely packed fibers, by using an established wet-spinning solution process. We find that fiber properties are mainly controlled by CNT aspect ratio and that sample purity is important for effective spinning. Properties appear largely unaffected by CNT diameter, number of walls, and graphitic character (determined by Raman G/D ratio) as long as the fibers comprise thin few-walled CNTs with high G/D ratio (above ∼20). We show that both strength and conductivity can be improved simultaneously by assembling high aspect ratio CNTs, producing continuous CNT fibers with an average tensile strength of 2.4 GPa and a room temperature electrical conductivity of 8.5 MS/m, ∼2 times higher than the highest reported literature value (∼15% of copper's value), obtained without postspinning doping. This understanding of the relationship of intrinsic CNT parameters to macroscopic fiber properties is key to guiding CNT synthesis and continued improvement of fiber properties, paving the way for CNT fiber introduction in large-scale aerospace, consumer electronics, and textile applications.

We demonstrate that the length of carbon nanotubes (CNTs) can be determined simply and accurately from extensional viscosity measurements of semidilute CNT solutions. The method is based on measuring the extensional viscosity of CNT solutions in chlorosulfonic acid with a customized capillary thinning rheometer and determining CNT aspect ratio from the theoretical relation between extensional viscosity and aspect ratio in semidilute solutions of rigid rods. We measure CNT diameter d by transmission electron microscopy (TEM) and arrive at CNT length L. By studying samples grown by different methods, we show that the method works well for CNT lengths ranging from 0.4 to at least 20 μm, a wider range than for previous techniques. Moreover, we measure the isotropic-to-nematic transition concentration (i.e., isotropic cloud point) φiso of CNT solutions and show that this transition follows Onsager-like scaling φiso ∼ d/L. We characterize the length distributions of CNT samples by combining the measurements of ...