The present disclosure relates generally to carbon fibers having high tensile strength and modulus of elasticity, as well as a process for the manufacture of such carbon fiber. The process comprises spinning a polymer/solvent solution into a solvent/water bath in the range of 78%-85% solvent, thereby producing a dense fiber structure, and subsequently carbonizing the polymer precursor fiber at a lower than typical carbonization temperature to form carbon fibers.

A carbon nanotube sheet structure includes: a carbon nanotube sheet; a first base material including a first base material surface facing the carbon nanotube sheet; and a first spacer providing a gap between the carbon nanotube sheet and the first base material. A first base material surface of the first base material includes a first region on which the first spacer is provided and a second region on which the first spacer is not provided. The first base material is spaced apart from the carbon nanotube sheet at the second region on the first base material surface.

A nanofiber structure applicator is described that can remove two substrates from opposing major surfaces of a nanofiber structure. The two substrates can have differing adhesive strengths with the nanofiber forest. This difference in adhesive strength can be used to reorient nanofibers that form the nanofiber structure relative to the final surface on which they are applied. This reorienting of the individual nanofibers within a nanofiber structure can be used to tailor some of the properties of the nanofiber structure. Furthermore, the nanofiber structure applicator is configured can improve the convenience with which a nanofiber structure can be transported and applied to an application surface.

A nanofiber structure applicator is described that can remove two substrates from opposing major surfaces of a nanofiber structure. The two substrates can have differing adhesive strengths with the nanofiber forest. This difference in adhesive strength can be used to reorient nanofibers that form the nanofiber structure relative to the final surface on which they are applied. This reorienting of the individual nanofibers within a nanofiber structure can be used to tailor some of the properties of the nanofiber structure. Furthermore, the nanofiber structure applicator is configured can improve the convenience with which a nanofiber structure can be transported and applied to an application surface.

A method of producing advanced carbon materials can include providing coal to a processing facility, beneficiating the coal to remove impurities from the coal, processing the beneficiated coal to produce a pitch, and treating the pitch to produce an advanced carbon material such as carbon fibers, carbon nanotubes, graphene, resins, polymers, biomaterials, or other carbon materials.

A method of producing advanced carbon materials can include providing coal to a processing facility, beneficiating the coal to remove impurities from the coal, processing the beneficiated coal to produce a pitch, and treating the pitch to produce an advanced carbon material such as carbon fibers, carbon nanotubes, graphene, resins, polymers, biomaterials, or other carbon materials.

A method of producing Stress Activated Pyrolytic Carbon-Carbon NanoTube (SAPC-CNT) fibers is disclosed. The fibers are a composite consisting of a tubular core of pristine graphite planes that include carbon nanotubes (CNTs) surrounded by semi-graphitic carbon material that includes Stress Activated Pyrolytic Carbon (SAPC), the SAPC being characterized by wavy graphite planes ranging from 0.1 nm to 1 nm and oriented parallel to the axis of each fiber, the semi-graphitic carbon material also being characterized by an inclusion of 4 to 10 atomic percent of nitrogen heteroatoms, the nitrogen heteroatoms including an above 60% of quaternary and pyridinic nitrogen groups.

A method of producing Stress Activated Pyrolytic Carbon-Carbon NanoTube (SAPC-CNT) fibers is disclosed. The fibers are a composite consisting of a tubular core of pristine graphite planes that include carbon nanotubes (CNTs) surrounded by semi-graphitic carbon material that includes Stress Activated Pyrolytic Carbon (SAPC), the SAPC being characterized by wavy graphite planes ranging from 0.1 nm to 1 nm and oriented parallel to the axis of each fiber, the semi-graphitic carbon material also being characterized by an inclusion of 4 to 10 atomic percent of nitrogen heteroatoms, the nitrogen heteroatoms including an above 60% of quaternary and pyridinic nitrogen groups.

A fiber comprises a bulk material comprising: one or more of carbon, silicon, boron, silicon carbide, and boron nitride; and a metal or metal alloy whose affinity for oxygen is greater than that of the bulk material. At least a first portion of the metal or metal alloy is present at the entrance to grain boundaries at the surface of the fiber and within the fiber to a depth of at least 1 micron from the fiber surface. A method of improving a fiber comprises heating a fiber in an inert atmosphere to 900-1300 C for sufficient time to allow at least some of a metal or metal alloy, placed on the fiber, to diffuse and/or flow into and along grain boundaries to a depth of at least 1 micron. The metal or metal alloy has a greater affinity for oxygen than that of the fiber bulk material.

A fiber comprises a bulk material comprising: one or more of carbon, silicon, boron, silicon carbide, and boron nitride; and a metal or metal alloy whose affinity for oxygen is greater than that of the bulk material. At least a first portion of the metal or metal alloy is present at the entrance to grain boundaries at the surface of the fiber and within the fiber to a depth of at least 1 micron from the fiber surface. A method of improving a fiber comprises heating a fiber in an inert atmosphere to 900-1300 C for sufficient time to allow at least some of a metal or metal alloy, placed on the fiber, to diffuse and/or flow into and along grain boundaries to a depth of at least 1 micron. The metal or metal alloy has a greater affinity for oxygen than that of the fiber bulk material.