Wet‐spinning and carbonization of graphene/PAN‐based fibers: Toward improving the properties of carbon fibers

3D printing of heterogeneous microfibers with multi-hollow structure via microfluidic spinning

Tissues with tubular structures play important roles in the human bodies, such as mass transport, nutrition exchange, and waste filtration. However, it remains a challenge to generate micro-scaffolds with well-defined luminal structure in biomedical field. In this study, we proposed a novel method to fabricate multi-component microfibers with multi-hollow structure via microfluidic spinning, which can subsequently be integrated with 3D printing for tissue-like block assembling. To achieve this goal, we fabricated a microchip using a 3D printed template with adjustable heights. Utilizing this microchip, we successfully generated the Calcium alginate microfibers with multi-components and defined hollow structures in a controllable manner. Then this microfluidic spinning method was integrated with a 3D mobile platform to assemble the microfibers into a grid-like 3D architecture. The resulted 3D scaffolds exhibited good organization and maintained the hollow structure of the fibers. Furthermore, we successfully developed a bronchus model utilizing this strategy by loading pulmonary bronchial epithelium cells and endothelial cells into microfibers with two hollow structures. The present strategy provides a potential platform to rebuild the lumen-like tissues using microfibers.

Designing Materials and Processes for Strong Polyacrylonitrile Precursor Fibers

Although polyacrylonitrile (PAN)-based carbon fibers have been successfully commercialized owing to their excellent material properties, their actual mechanical performance is still much lower than the theoretical values. Meanwhile, there is a growing demand for the use of superior carbon fibers. As such, many studies have been conducted to improve the mechanical performance of carbon fibers. Among the various approaches, designing a strong precursor fiber with a well-developed microstructure and morphology can constitute the most effective strategy to achieve superior performance. In this review, the efforts used to modulate materials, processing, and additives to deliver strong precursor fibers were thoroughly investigated. Our work demonstrates that the design of materials and processes is a fruitful pathway for the enhancement of the mechanical performance of carbon fibers.

Microstructure-Controlled Polyacrylonitrile/Graphene Fibers over 1 Gigapascal Strength

Controlling the microstructures in fibers, such as crystalline structures and microvoids, is a crucial challenge for the development of mechanically strong graphene fibers (GFs). To date, although GFs graphitized at high temperatures have exhibited high tensile strength, GFs still have limited the ultimate mechanical strength owing to the presence due to the structural defects, including the imperfect alignment of graphitic crystallites and the presence of microsized voids. In this study, we significantly enhanced the mechanical strength of GF by controlling microstructures of fibers. GF was hybridized by incorporating polyacrylonitrile (PAN) in the graphene oxide (GO) dope solution. In addition, we controlled the orientation of the inner structure by applying a tensile force at 800 °C. The results suggest that PAN can act as a binder for graphene sheets and can facilitate the rearrangement of the fiber's microstructure. PAN was directionally carbonized between graphene sheets due to the catalytic effect of graphene. The resulting hybrid GFs successfully displayed a high strength of 1.10 GPa without undergoing graphitization at extremely high temperatures. We believe that controlling the alignment of nanoassembled structure is an efficient strategy for achieving the inherent performance characteristics of graphene at the level of multidimensional structures including films and fibers.

Rapid In Situ Polymerization of Polyacrylonitrile/Graphene Oxide Nanocomposites as Precursors for High-Strength Carbon Nanofibers

Graphene oxide (GO) has been widely used as an additive of polyacrylonitrile (PAN)-based carbon nanofibers (CNFs) to optimize its crystal structure and improve the mechanical performances of nanofibers. However, the homogeneous dispersion of GO nanosheets among entangled PAN molecular chains is always challenging, and the poor dispersion of GO severely limits its positive effects on both the structure and performances of CNFs. Considering this issue, this paper provides for the first time an effective solution to achieve rapid and uniform introduction of GO in PAN-based nanofibers via in situ polymerization, and the optimization of the nanofiber structure by GO is systematically studied in three consecutive stages (polymerization, electrospinning, and carbonization) of the production process. During in situ polymerization, PAN is tightly attached on GO nanosheets to form PAN/GO nanocomposites, and this interaction is maintained throughout the spinning process. Not only the arrangement of PAN molecular chains but also the crystal size of the final turbostratic structure of CNFs is considerably improved by the interaction between PAN and GO. Besides, the direct proof that GO nanosheets promote the crystallization and orientation of the nanofiber matrix is presented. As a result, the tensile strength of CNFs is remarkably increased by 2.45 times with 0.5 wt % addition of GO. In summary, this paper provides a method for efficiently introducing nanoscale additives into PAN-based nanofibers and gives insights into the production of high-performance CNFs with the addition of GO.

Effect of lignin-based monomer on controlling the molecular weight and physical properties of the polyacrylonitrile/lignin copolymer

In this work, lignin was grafted with acrylonitrile to control the molecular weights and molecular architecture of polyacrylonitrile (PAN)/lignin copolymer. Lignin-acrylonitrile monomer (LA-AN) and its copolymers with AN were synthesized successfully. First, lignin was aminated (LA) and then grafted with 2-chloroacrylonitrile to prepare LA-AN. The copolymerization of LA-AN and AN was carried out using 2,2-azobis(2-methylpropionitrile) as initiator. The modification, grafting, and copolymerization were confirmed with Fourier transform infrared spectroscopy, proton nuclear magnetic resonance spectroscopy, and X-ray photoelectron spectroscopy. Contrary to the previous studies, gel permeation chromatography showed that the molecular weight of the copolymers was increased significantly due to the presence of lignin (up to 203,944). Viscosity analysis revealed that the addition of lignin reduces the viscosity of the copolymer solution. While thermogravimetric analysis showed improvement in the degradation temperature, and lowering of the melt temperature, as revealed by differential scanning calorimetry. These findings indicated that the attaching acrylonitrile on lignin molecules result in control of the molecular weight and molecular structure of PAN/Lignin copolymers which results in enhanced solubility, spinnability, and other properties associated with molecular weight.

Graphene reinforced carbon fibers

The superlative strength-to-weight ratio of carbon fibers (CFs) can substantially reduce vehicle weight and improve energy efficiency. However, most CFs are derived from costly polyacrylonitrile (PAN), which limits their widespread adoption in the automotive industry. Extensive efforts to produce CFs from low cost, alternative precursor materials have failed to yield a commercially viable product. Here, we revisit PAN to study its conversion chemistry and microstructure evolution, which might provide clues for the design of low-cost CFs. We demonstrate that a small amount of graphene can minimize porosity/defects and reinforce PAN-based CFs. Our experimental results show that 0.075 weight % graphene-reinforced PAN/graphene composite CFs exhibits 225% increase in strength and 184% enhancement in Young's modulus compared to PAN CFs. Atomistic ReaxFF and large-scale molecular dynamics simulations jointly elucidate the ability of graphene to modify the microstructure by promoting favorable edge chemistry and polymer chain alignment.

Simple Fabrication of Multicomponent Heterogeneous Fibers for Cell Co-Culture via Microfluidic Spinning

Microfluidic spinning, as a combination of wet spinning and microfluidic technology, has been used to develop microfibers with special structures to facilitate cell 3D culture/co-culture and microtissue formation in vitro. In this study, a simple microchip-based microfluidic spinning strategy is presented for the fabrication of multicomponent heterogeneous calcium alginate microfibers. The use of two kinds of microchip enables the one-step preparation of multicomponent heterogeneous microfibers with various arrangement patterns, including the preparation of one-, two-, and three-component microfibers by a two-layer microchip and preparation of four component microfibers with different arrangement by a membrane-sandwiched three-layer microchip. The obtained microfibers could be used to encapsulate various kinds of cells, such as the human non-small cell lung cancer cell NCI-H1650, the human fetal lung fibroblast HFL1, the normal pulmonary bronchial epithelial cell 16HBE, and human umbilical vein endothelial cells. By adding chitosan to the medium to keep the fibers stable, 3D long-term in vitro cell co-culture has been carried out up to 21 days. This method is very simple and easy to operate, continuously produces spatially well-defined heterogeneous microfibers, has important applications for composite functional biomaterials, and shows great potential in organs-on-a-chip and biomimetic systems.