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) × 104 S m2 kg-1, 56% higher than Cu. Experimental and simulation results show that oxygen-containing functional groups on the surface of a wet-spun 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 × 105 A cm-2, three times that of commercial Cu wires.
Keywords: current carrying capacity; fiber; magnetron sputtering; single-walled carbon nanotube; specific electrical conductivity.