Air gap spinning of a cellulose solution in [ DBNH ][ OAc ] ionic liquid with a novel vertically arranged spinning bath to simulate a closed loop operation in the Ioncell® process

Upcycling of cellulosic textile waste with bacterial cellulose via Ioncell® technology

Currently the textile industry relies strongly on synthetic fibres and cotton, which contribute to many environmental problems. Man-made cellulosic fibres (MMCF) can offer sustainable alternatives. Herein, the development of Lyocell-type MMCF using bacterial cellulose (BC) as alternative raw material in the Ioncell® spinning process was investigated. BC, known for its high degree of polymerization (DP), crystallinity and strength was successfully dissolved in the ionic liquid (IL) 1,5-diazabicyclo[4.3.0]non-5-enium acetate [DBNH][OAc] to produce solutions with excellent spinnability. BC staple fibres displayed good mechanical properties and crystallinity (CI) and were spun into a yarn which was knitted into garments, demonstrating the potential of BC as suitable cellulose source for textile production. BC is also a valuable additive when recycling waste cellulose textiles (viscose fibres). The high DP and Cl of BC enhanced the spinnability in a viscose/BC blend, consequently improving the mechanical performance of the resulting fibres, as compared to neat viscose fibres.

Force-Induced Alignment of Nanofibrillated Bacterial Cellulose for the Enhancement of Cellulose Composite Macrofibers

Bacterial cellulose, as an important renewable bioresource, exhibits excellent mechanical properties along with intrinsic biodegradability. It is expected to replace non-degradable plastics and reduce severe environmental pollution. In this study, using dry jet-wet spinning and stretching methods, we fabricate cellulose composite macrofibers using nanofibrillated bacterial cellulose (BCNFs) which were obtained by agitated fermentation. Ionic liquid (IL) was used as a solvent to perform wet spinning. In this process, force-induced alignment of BCNFs was applied to enhance the mechanical properties of the macrofibers. The results of scanning electron microscopy revealed the well-aligned structure of BCNF along the fiber axis. The fiber prepared with an extrusion rate of 30 m min-1 and a stretching ratio of 46% exhibited a strength of 174 MPa and a Young's modulus of 13.7 GPa. In addition, we investigated the co-spinning of carboxymethyl cellulose-containing BCNF with chitosan using IL as a "container", which indicated the compatibility of BCNFs with other polysaccharides. Recycling of the ionic liquid was also verified to validate the sustainability of our strategy. This study provides a scalable method to fabricate bacterial cellulose composite fibers, which can be applied in the textile or biomaterial industries with further functionalization.

Recent Advances in Cellulose-Based Hydrogels Prepared by Ionic Liquid-Based Processes

This review summarizes the recent advances in preparing cellulose hydrogels via ionic liquid-based processes and the applications of regenerated cellulose hydrogels/iongels in electrochemical materials, separation membranes, and 3D printing bioinks. Cellulose is the most abundant natural polymer, which has attracted great attention due to the demand for eco-friendly and sustainable materials. The sustainability of cellulose products also depends on the selection of the dissolution solvent. The current state of knowledge in cellulose preparation, performed by directly dissolving in ionic liquids and then regenerating in antisolvents, as described in this review, provides innovative ideas from the new findings presented in recent research papers and with the perspective of the current challenges.

Effects of coagulating conditions on the crystallinity, orientation and mechanical properties of regenerated cellulose fibers

Fabricating regenerated cellulose fibers using ionic liquids is a novel and green technology. Structural changes of regenerated fibers during forming process affect the macroscopic properties of regenerated fibers. The study of the regenerated fiber forming mechanisms in conditions relevant to fiber spinning processes, especially in the process of dry-wet spinning, is necessary and meaningful. In this work, regenerated cellulose fibers were prepared from wood pulp meal with 1-ethyl-3-methylimidazolium diethylphosphate ([Emim]DEP) under various coagulation bath compositions. The effect of coagulating conditions on the properties of regenerated fibers was investigated, and the internal structures and mechanical properties of regenerated fibers were characterized. The results indicated that regenerated cellulose fibers eventually developed differences in their internal structure and mechanical properties due to the different diffusion rates between spinning solution and coagulation bath. Ethanol significantly reduced the crystallinity and orientation, and elongation increased greatly. In addition, both the crystallinity and orientation of regenerated fibers increased with the decreased of ethanol content in coagulation bath when ethanol content >70 %, while the elongation was reversed. What's more, the scanning electron microscopy results revealed that the regenerated cellulose fibers' surfaces were homogeneous, indicating the regenerated fibers have great potential in the application of textile fabrics.

Fiber Spinning from Cellulose Solutions in Imidazolium Ionic Liquids: Effects of Natural Antioxidants on Molecular Weight, Dope Discoloration, and Yellowing Behavior

Spinning of cellulosic fibers requires the prior dissolution of cellulose. 3-Alkyl-1-methylimidazolium ionic liquids have proven to be suitable solvents for that purpose, but the degradation of cellulose in the spinning dope can be severe. Suitable stabilizers are therefore required that prevent cellulose degradation, but do not adversely affect spinnability or the long-term yellowing behavior of the fibers. A group of twelve renewables-based antioxidants was selected for stabilizing 5% cellulose solutions in the ionic liquids and their effects on cellulose integrity, dope discoloration, and aging behavior were tested by gel permeation chromatography (GPC) and ISO brightness measurements. Propyl gallate (a gallic acid derivative), hydroxytyrosol (from olives), and tocopheramines (a vitamin E derivative) performed best in the three test categories, minimizing both cellulose degradation, chromophore formation in the spinning dope, and yellowing upon accelerating aging of the spun fibers. The use of these stabilizers for cellulose solutions in the imidazolium-based solvent system can therefore be recommended from the point of view of both performance and sustainability.

Hollow Filaments Synthesized by Dry-Jet Wet Spinning of Cellulose Nanofibrils: Structural Properties and Thermoregulation with Phase-Change Infills

We use dry-jet wet spinning in a coaxial configuration by extruding an aqueous colloidal suspension of oxidized nanocellulose (hydrogel shell) combined with airflow in the core. The coagulation of the hydrogel in a water bath results in hollow filaments (HF) that are drawn continuously at relatively high rates. Small-angle and wide-angle X-ray scattering (SAXS/WAXS) reveals the orientation and order of the cellulose sheath, depending on the applied shear flow and drying method (free-drying and drying under tension). The obtained dry HF show Young's modulus and tensile strength of up to 9 GPa and 66 MPa, respectively. Two types of phase-change materials (PCM), polyethylene glycol (PEG) and paraffin (PA), are used as infills to enable filaments for energy regulation. An increased strain (9%) is observed in the PCM-filled filaments (HF-PEG and HF-PA). The filaments display similar thermal behavior (dynamic scanning calorimetry) compared to the neat infill, PEG, or paraffin, reaching a maximum latent heat capacity of 170 J·g^-1 (48-55 °C) and 169 J·g^-1 (52-54 °C), respectively. Overall, this study demonstrates the facile and scalable production of two-component core-shell filaments that combine structural integrity, heat storage, and thermoregulation properties.

Production of rayon fibres from cellulosic pulps: State of the art and current developments

The increasing demand for cellulosic fibres is continuously driven by the growing earth population and requirements of the textile industry. The annual cotton production of ca. 25 million tons is no longer enough to meet the market demands. This market gap of cellulosic fibres is progressively filled by regenerated cellulosic fibres derived from the dissolving pulp. The conventional industrial process of viscose production is far from being environmentally friendly due to the use of hazardous reagents. Alternatively, new trends in the production of regenerated fibres are related to the direct dissolution of cellulose in appropriate environmentally sound recyclable solvents, allowing high quality rayon fibres. This article reviews the sources of dissolving pulps used for the production of viscose and its quality parameters related to the performance of viscose production. The prospective cellulose regeneration processes, both commercialized and under development, are reviewed regarding current and future developments in the area.