High-Modulus Low-Cost Carbon Fibers from Polyethylene Enabled by Boron Catalyzed Graphitization

Enhancement of thermal conductivity and abrasion resistance of woody carbon fiber composites via boride catalysis

In order to investigate the effect of boron element on liquefied wood carbon fibers and their composites, boric acid and boron carbide were utilized to modify liquefied wood resin through copolymerization and blending methods respectively. Then boric acid-modified liquefied wood carbon fiber (BA-WCF) and boron carbide-modified liquefied wood carbon fiber (BC-WCF) were produced via melt spinning, curing, and carbonization treatments. As expected, this modification approach effectively prevents the formation of skin-core structures and accelerates the evolution of a graphite microcrystalline structure, thereby enhancing the mechanical properties of the carbon fibers. Particularly, the tensile strength and elongation at break of BA-WCF increased to 331.57 MPa and 7.57 % respectively, representing increments of 117 % and 86 % compared to the conventional fibers. Furthermore, the as-fabricated carbon fiber/resin composites (CFPRs), composing of BA-WCF or BC-WCF as fillers and liquefied wood resin as matrix, exhibited excellent interlaminar shear strength, outstanding abrasion resistance, and well thermal conductivity, as well as electrical performance, significantly outperforming the conventional carbon fiber/phenolic resin composites. The friction rate of BC-WP/BA-WCF/CF was 2.37 %, while its thermal conductivity could reach 1.927 W/(m·K). These promising attributes lay the groundwork for the development of high-performance carbon fiber-based materials, fostering their widespread utilization across various industries.

A Universal Method for Regulating Carbon Microcrystalline Structure for High-Capacity Sodium Storage: Binding Energy As Descriptor

Sodium-ion batteries (SIBs) are attracting worldwide attention due to their multiple merits including abundant reserve and safety. However, industrialization is challenged by the scarcity of high-performance carbon anodes with high specific capacities. Here, we report the metal-assisted microcrystalline structure regulation of carbon materials to achieve high-capacity sodium storage. Systematic investigations of in situ thermal-treatment X-ray diffraction and multiple spectroscopies uncover the regulation mechanism of constructing steric hindrance (C-O-C bonds) to restrain the aromatic polycondensation reaction. The carbon precursor of polycyclic aromatic hydrocarbon-type pitch contributes to a high carbon yield rate (40%) compared with those of resin and biomass precursors. The as-synthesized carbon materials deliver high capacities of up to 390 mAh g-1, surpassing many reported carbon anodes for SIBs. Through correlating specific capacity with ID/IG values in Raman spectra and theoretical calculation of carbon materials regulated by different metal elements (Mn, Nb, Ce, Cr, and V), we identify and propose the binding energy as the descriptor for characterizing the capability of regulating the carbon microcrystalline structure to promote sodium storage. This work provides a universal method for regulating the carbon structure, which may lead to the controlled design and fabrication of carbon materials for energy storage and conversion and beyond.

Boric Acid as A Low-Temperature Graphitization Aid and Its Impact on Structure and Properties of Cellulose-Based Carbon Fibers

In the present paper, a scalable, economically feasible, and continuous process for making cellulose-based carbon fibers (CFs) is described encompassing precursor spinning, precursor additivation, thermal stabilization, and carbonization. By the use of boric acid (BA) as an additive, the main drawback of cellulose-based CFs, i.e., the low carbon yield, is overcome while maintaining a high level of mechanical properties. This is demonstrated by a systematic comparison between CFs obtained from a BA-doped and an un-doped cellulose precursor within a temperature range for carbonization between 1000 and 2000 °C. The changes in chemical composition (via elemental analysis) and physical structure (via X-ray scattering) as well as the mechanical and electrical properties of the resulting CFs were investigated. It turned out that, in contrast to current opinion, the catalytic effect of boron in the formation of graphite-like structures sets in already at 1000 °C. It becomes more and more effective with increasing temperature. The catalytic effect of boron significantly affects crystallite sizes (La, Lc), lattice plane spacings (d002), and orientation of the crystallites. Using BA, the carbon yield increased by 71%, Young's modulus by 27%, and conductivity by 168%, reaching 135,000 S/m. At the same time, a moderate decrease in tensile strength by 25% and an increase in density of 14% are observed.

Influence of Oxygen Uptake on Pitch Carbon Fiber

Carbon fiber precursor materials, such as polyacrylonitrile, pitch, and cellulose/rayon, require thermal stabilization to maintain structural integrity during conversion into carbon fiber. Thermal stabilization mitigates undesirable decomposition and liquification of the fibers during the carbonization process. Generally, the thermal stabilization of mesophase pitch consists of the attachment of oxygen-containing functional groups onto the polymeric structure. In this study, the oxidation of mesophase pitch precursor fibers at various weight percentage increases (1, 3.5, 5, 7.5 wt%) and temperatures (260, 280, 290 °C) using in situ differential scanning calorimetry and thermogravimetric analysis is investigated. The results are analyzed to determine the effect of temperature and weight percentage increase on the stabilization process of the fibers, and the fibers are subsequently carbonized and tested for tensile mechanical performance. The findings provide insight into the relationship between stabilization conditions, fiber microstructure, and mechanical properties of the resulting carbon fibers.

Hydrophobic, Sustainable, High-Barrier Regenerated Cellulose Film via a Simple One-Step Silylation Reaction

With the increasing importance of environmental protection, high-performance biopolymer films have received considerable attention as effective alternatives to petroleum-based polymer films. In this study, we developed hydrophobic regenerated cellulose (RC) films with good barrier properties through a simple gas-solid reaction via the chemical vapor deposition of alkyltrichlorosilane. RC films were employed to construct a biodegradable, free-standing substrate matrix, and methyltrichlorosilane (MTS) was used as a hydrophobic coating material to control the wettability and improve the barrier properties of the final films. MTS readily coupled with hydroxyl groups on the RC surface through a condensation reaction. We demonstrated that the MTS-modified RC (MTS/RC) films were optically transparent, mechanically strong, and hydrophobic. In particular, the obtained MTS/RC films exhibited a low oxygen transmission rate of 3 cm³/m² per day and a low water vapor transmission rate of 41 g/m² per day, which are superior to those of other hydrophobic biopolymer films.

Additive Manufacturing of Carbon Using Commodity Polypropylene

Carbon materials are essential to the development of modern society with indispensable use in various applications, such as energy storage and high-performance composites. Despite great progress, on-demand carbon manufacturing with control over 3D macroscopic configuration is still an intractable challenge, hindering their direct use in many areas requiring structured materials and products. This work introduces a simple and scalable method to generate complex, large-scale carbon structures using easily accessible materials and technologies. 3D-printed, commercial polypropylene (PP) parts can be thermally stabilized through cracking-facilitated diffusion and crosslinking. The newly elucidated mechanism from this work allows thick PP parts to yield carbonaceous products with complex structures through a subsequent pyrolysis step. The approach for enabling PP-to-carbon conversion has consistent product yield and controlled dimensional shrinkage. Under optimized processing conditions, these PP-derived carbons exhibit robust mechanical properties and excellent joule heating performance, demonstrated by their versatile use as heating elements. Furthermore, this process can be extended to recycled PP, enabling the conversion of waste plastic materials to value-added products. This work provides an innovative approach to create structured carbon materials with direct access to complex geometry, which can be transformative to, and broadly benefit, many important technological applications.

Controllable 3D Flower-Like Ag-CF Electrodes as Flexible Marine Electric Field Sensors with High Stability

Construction of three-dimensional (3D) flower-like nanostructures with controlled morphologies has emerged as an attractive tool by scientists in the marine electric field sensor research field due to their peculiar structural features. Herein, novel 3D flower-like Ag-CF capacitive composite electrodes have been created by an eco-friendly water-bath strategy via AgNO₃ as a sliver source and subsequently compounded with carbon fibers (CFs) pretreated by thermal oxidation. A series of electrode samples with various morphologies obtained by modulating different reaction times and temperatures bring about the dominant formation mechanism of these nanostructures and the influence behavior on the CF electrode in detail. Especially, the 3D flower-like Ag-CF electrode shows a large surface area acquired under the conditions of 80 °C and 15 min, which can provide more electroactive sites in electrochemical analysis and exhibit a maximum areal specific capacitance of 619.75 mF·cm^-2 at a scanning speed of 10 mV·s^-1. This is mainly due to the synergistic behavior of the unique 3D flower-like morphology and the large specific surface area of CFs. Furthermore, a cylinder-shaped Ag-CF sensor is designed, which delivers a superior potential difference of 33.08 μV, a potential difference drift of 18.62 μV/24 h for 30 days, and a self-noise of 0.92 nV/rt (Hz)@1 Hz. In this work, the intriguing synthesis strategy can be a promising facile approach to manufacture the controllable 3D flower-like Ag-CF electrode for electric field sensor applications.

2D-Topology-Seeded Graphitization for Highly Thermally Conductive Carbon Fibers

Highly thermally conductive carbon fibers (CFs) have become an important material to meet the increasing demand for efficient heat dissipation. To date, high thermal conductivity has been only achieved in specific pitch-based CFs with high crystallinity. However, obtaining high graphitic crystallinity and high thermal conductivity beyond pitch-CFs remains a grand challenge. Here, a 2D-topology-seeded graphitization method is presented to mediate the topological incompatibility in graphitization by seeding 2D graphene oxide (GO) sheets into the polyacrylonitrile (PAN) precursor. Strong mechanical strength and high thermal conductivity up to 850 W m^{- 1} K^-1 are simultaneously realized, which are one order of magnitude higher in conductivity than commercial PAN-based CFs. The self-oxidation and seeded graphitization effect generate large crystallite size and high orientation to far exceed those of conventional CFs. Topologically seeded graphitization, verified in experiments and simulations, allows conversion of the non-graphitizable into graphitizable materials by incorporating 2D seeds. This method extends the preparation of highly thermally conductive CFs, which has great potential for lightweight thermal-management materials.

Cost-effective carbon fiber precursor selections of polyacrylonitrile-derived blend polymers: carbonization chemistry and structural characterizations

Blending polyacrylonitrile (PAN) with plastic wastes and bio-based polymers provides a convenient and inexpensive method to realize cost-effective carbon fiber (CF) precursors. In this work, PAN-based blend precursors are investigated using ReaxFF reactive molecular dynamics simulations with respect to the formation of all-carbon rings, the evolutions of oxygen-containing and nitrogen-containing species, and the migration of carbon atoms to form turbostratic graphene. From these simulations, we identify that PAN/cellulose (CL) blend manifests the highest carbon yield and the most substantial all-carbon ring formation. This ReaxFF-based finding is confirmed by Raman and TEM experiments indicating high crystallinity for PAN/CL-derived blend CFs. We trace the pathway of gasification and carbonization of PAN/CL to elaborate the mechanism of the formation of all-carbon ring networks. We discover that the acetals of CL can catalyze the cyclization of the blend precursor, allowing for the search for CL derivatives or the other kinds of bio-based polymers with similar functionalities as alternative blends. In addition, we examine the structural characteristics using the carbon-carbon (C-C) radial distribution functions, C-C bond length distributions, and sp² C atom ratios for the four representative precursors, i.e., PAN, oxidized PAN, PAN/nylon 6,6, and PAN/CL. Our simulation results show the most extensive all-carbon ring cluster and graphitic structure growths for PAN/CL. Therefore, we propose PAN/CL as a cost-effective alternative CF precursor, since (a) CL is naturally abundant and eco-friendly for production, (b) the blend precursor PAN/CL does not require oxidation treatment, (c) PAN/CL has a high carbon yield with substantial all-carbon ring formation, and (d) PAN/CL based CFs potentially provide a mechanical property enhancement.

Multifunctional Carbon Fibers from Chemical Upcycling of Mask Waste

Over the past years, disposable masks have been produced in unprecedented amounts due to the COVID-19 pandemic. Their increased use imposes significant strain on current waste management practices including landfilling and incineration. This results in large volumes of discarded masks entering the environment as pollutants, and alternative methods of waste management are required to mitigate the negative effects of mask pollution. While current recycling methods can supplement conventional waste management, the necessary processes result in a product with downgraded material properties and a loss of value. This work introduces a simple method to upcycle mask waste into multifunctional carbon fibers through simple steps of thermal stabilization and pyrolysis. The pre-existed fibrous structure of polypropylene masks can be directly converted into carbonaceous structures with high degrees of carbon yield, that are inherently sulfur-doped, and porous in nature. The mask-derived carbon product demonstrates potential use in multiple applications such as for Joule heating, oil adsorption, and the removal of organic pollutants from aqueous environments. We believe that this process can provide a useful alternative to conventional waste management by converting mask waste generated during the COVID-19 pandemic into a product with enhanced value.

Study on polyethylene-based carbon fibers obtained by sulfonation under hydrostatic pressure

Polyethylene based carbon fibers were studied using high density polyethylene(HDPE) fibers and linear low density polyethylene(LLDPE) fibers with various melt flow index. The draw ratio of the polyethylene fibers and the sulfonation mechanism were investigated under hydrostatic pressures of 1 and 5 bar in the first time. The influence of the melt flow index of polyethylene and types of polyethylene fibers on the sulfonation reaction was studied. Carbon fibers were prepared through the sulfonation of LLDPE fibers possessing side chains with a high melt flow index. The polyethylene fibers, which exhibited thermoplastic properties and plastic behavior, were cross-linked through the sulfonation process. Their thermal properties and mechanical properties changed to thermoset properties and elastic behavior. Although sulfonation was performed under a hydrostatic pressure of 5 bar, it was difficult to convert the highly oriented polyethylene fibers because of their high crystallinity, but partially oriented polyethylene fibers could be converted to carbon fibers. Therefore, the effect of fiber orientation on fiber crosslinking, which has not been reported in previous literature, has been studied in detail, and a new method of hydrostatic pressure sulfonation has been successful in thermally stabilizing polyethylene fiber. Hydrostatic sulfonation was performed using partially oriented LLDPE fibers with a melt flow index of 20 at 130 °C for 2.5 h under a hydrostatic pressure of 5 bar. The resulting fibers were carbonized under the following conditions: 1000 °C, 5 °C/min, and five minutes. Carbon fibers with a tensile strength of 2.03 GPa, a tensile modulus of 143.63 GPa, and an elongation at break of 1.42% were prepared.

Manufacturing Pitch and Polyethylene Blends-Based Fibres as Potential Carbon Fibre Precursors

The advantage of mesophase pitch-based carbon fibres is their high modulus, but pitch-based carbon fibres and precursors are very brittle. This paper reports the development of a unique manufacturing method using a blend of pitch and linear low-density polyethylene (LLDPE) from which it is possible to obtain precursors that are less brittle than neat pitch fibres. This study reports on the structure and properties of pitch and LLDPE blend precursors with LLDPE content ranging from 5 wt% to 20 wt%. Fibre microstructure was determined using scanning electron microscopy (SEM), which showed a two-phase region having distinct pitch fibre and LLDPE regions. Tensile testing of neat pitch fibres showed low strain to failure (brittle), but as the percentage of LLDPE was increased, the strain to failure and tensile strength both increased by a factor of more than 7. DSC characterisation of the melting/crystallization behaviour of LLDPE showed melting occurred around 120 °C to 124 °C, with crystallization between 99 °C and 103 °C. TGA measurements showed that for 5 wt%, 10 wt% LLDPE thermal stability was excellent to 800 °C. Blend pitch/LLDPE carbon fibres showed reduced brittleness combined with excellent thermal stability, and thus are a candidate as a potential precursor for pitch-based carbon fibre manufacturing.

Surface Pretreatment and Fabrication Technology of Braided Carbon Fiber Rope Aluminum Matrix Composite

Carbon fiber is mainly distributed in the shape of short fibers and continuous fiber bundles as the reinforcing phase in metal matrix composites, and it is seldom studied as braided rope shaped to reinforce the matrix. For this paper, the pretreatment and the surface metallization of the carbon fiber braided rope were studied. Besides, the casting experiments of aluminum-based carbon fiber braided rope composites were performed without external pressure. XPS analysis shows that the surface of the carbon fiber braided rope treated with ultrasonic degumming contains many hydrophilic oxygen-containing functional groups C-OH, C=O, COOH, etc., which can effectively improve the wettability between the carbon fiber braided rope and the aluminum matrix. SEM, EDS, and XRD were used to analyze the micromorphology and structure of the copper plating on the surface of carbon fiber braided ropes obtained from different pH plating solutions. When pH is 12, a continuous, uniform, and dense layer was formed on the surface of carbon fiber braided ropes. In addition, copper coating can effectively inhibit the formation of Al4C3 brittle phase. Finally, the mechanical properties results indicated that the tensile strength of the carbon fiber bundle and carbon fiber rope reinforced composite materials were 69 MPa and 83 MPa, respectively, indicating that the reinforcing effect of the carbon fiber rope is better than that of the carbon fiber bundle.