In this work, we report on the effective implementation of the direct and scalable floating catalyst method to synthesize self-supporting carbon nanotube (CNT) aerogels at high deposition rates. Through the adaptable process conditions, the highly porous and ultralight CNT aerogels with densities ranging from 0.55 to 32 mg/cm(3) are synthesized. The aerogels exhibit high porosity (> 98%) and surface areas of up to 170 m(2)/g with tortuous pores easy accessible to molecules of interest. Their superior electrical conductivity (up to 106 S/m), in comparison with CNT aerogels produced through other methods, indicates high potential for energy applications. The thermal conductivity has been observed to be within the range of 0.127-0.137 W/m.K as a consequence of the ultralight structure. Polymer infiltration and subsequent curing do not disturb the three-dimensional percolating CNT network and constitute an accessible method for the production of various lightweight polymeric composites. The polydimethylsiloxane-based composites (4.5% wt) with electrical conductivity enhanced by similar to 16 orders of magnitude and thermal conductivity double that of pure matrix are particularly promising for use in bio-integrated devices and flexible composites. (C) 2016 Elsevier Ltd. All rights reserved.
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