Strengthened PAN-based carbon fibers obtained by slow heating rate carbonization

Facile Preparation of Polyacrylonitrile-Based Activated Carbon Fiber Felts for Effective Adsorption of Dipropyl Sulfide

Activated carbon fibers (ACFs) derived from various polymeric fibers with the characteristics of a high specific surface area, developed pore structure, and good flexibility are promising for the new generation of chemical protection clothing. In this paper, a polyacrylonitrile-based ACF felt was prepared via the process of liquid phase pre-oxidation, along with a one-step carbonization and chemical activation method. The obtained ACF felt exhibited a large specific surface area of 2219.48 m2/g and pore volume of 1.168 cm3/g, as well as abundant polar groups on the surface. Owing to the developed pore structure and elaborated surface chemical property, the ACF felt possessed an intriguing adsorption performance for a chemical warfare agent simulant dipropyl sulfide (DPS), with the highest adsorption capacity being 202.38 mg/g. The effects of the initial concentration of DPS and temperature on the adsorption performance of ACF felt were investigated. Meanwhile, a plausible adsorption mechanism was proposed based on the kinetic analysis and fitting of different adsorption isotherm models. The results demonstrated that the adsorption process of DPS onto ACF felt could be well fitted with a pseudo-second-order equation, indicating a synergistic effect of chemical adsorption and physical adsorption. We anticipate that this work could be helpful to the design and development of advanced ACF felts for the application of breathable chemical protection clothing.

Insights into the carbonization mechanism of PAN-derived carbon precursor fibers and establishment of a kinetics-driven accelerated reaction template for atomistic simulation

To better understand the chemistry behind the carbonization process of the polyacrylonitrile (PAN)-based precursor fibers and provide a more authentic virtual counterpart of the process-inherited model for process optimization and rational performance design, we develop arrow-pushing reaction routes for primary exhaust gas product (H₂O/H₂/HCN/N₂/tar vapor) formation and a pragmatic kinetics-driven accelerated reaction template for atomistic simulation of the carbonization process overcoming traditional challenges in time scale discrepancy of the reaction-diffusion system. The results of enthalpy barriers from hybrid first principles calculations validate the rationality and sequence of conjectured reactions during the two-stage carbonization process. Conversion rates of the rate-determining steps under 300 s carbonization are also estimated based on Eyring's transition state theory realizing kinetics equivalency of the reaction extent. Process-control measurements are further demonstrated corresponding to the proposed mechanism. The iterative densified crosslinking scheme specially designed for the surface layer is implanted into the topological reaction molecular dynamics template and a series of highly devisable structural models during the whole evolutionary process from the pre-oxidized fiber to the pristine carbon fiber surface are successfully predicted. The ultimate structure of the model presents excellent similarity in carbon yield and elemental composition with the type II high strength carbon fiber surface.

Evaluation of Keratin-Cellulose Blend Fibers as Precursors for Carbon Fibers

One main challenge to utilize cellulose-based fibers as the precursor for carbon fibers is their inherently low carbon yield. This study aims to evaluate the use of keratin in chicken feathers, a byproduct of the poultry industry generated in large quantities, as a natural charring agent to improve the yield of cellulose-derived carbon fibers. Keratin-cellulose composite fibers are prepared through direct dissolution of the pulp and feather keratin in the ionic liquid 1,5-diazabicyclo[4.3.0]non-5-enium acetate ([DBNH]OAc) and subsequent dry jet wet spinning (so-called Ioncell process). Thermogravimetric analysis reveals that there is an increase in the carbon yield by ∼53 wt % with 30 wt % keratin incorporation. This increase is comparable to the one observed for lignin-cellulose composite fibers, in which lignin acts as a carbon booster due to its higher carbon content. Keratin, however, reduces the mechanical properties of cellulose precursor fibers to a lesser extent than lignin. Keratin introduces nitrogen and induces the formation of pores in the precursor fibers and the resulting carbon fibers. Carbon materials derived from the keratin-cellulose composite fiber show potential for applications where nitrogen doping and pores or voids in the carbon are desirable, for example, for low-cost bio-based carbons for energy harvest or storage.

Atmospheric Pressure Plasma-Jet Treatment of PAN-Nonwovens—Carbonization of Nanofiber Electrodes

Carbon nanofibers are produced from dielectric polymer precursors such as polyacrylonitrile (PAN). Carbonized nanofiber nonwovens show high surface area and good electrical conductivity, rendering these fiber materials interesting for application as electrodes in batteries, fuel cells, and supercapacitors. However, thermal processing is slow and costly, which is why new processing techniques have been explored for carbon fiber tows. Alternatives for the conversion of PAN-precursors into carbon fiber nonwovens are scarce. Here, we utilize an atmospheric pressure plasma jet to conduct carbonization of stabilized PAN nanofiber nonwovens. We explore the influence of various processing parameters on the conductivity and degree of carbonization of the converted nanofiber material. The precursor fibers are converted by plasma-jet treatment to carbon fiber nonwovens within seconds, by which they develop a rough surface making subsequent surface activation processes obsolete. The resulting carbon nanofiber nonwovens are applied as supercapacitor electrodes and examined by cyclic voltammetry and impedance spectroscopy. Nonwovens that are carbonized within 60 s show capacitances of up to 5 F g−1.

Electrospun Polyacrylonitrile/Lignin/Poly(Ethylene Glycol)-Based Porous Activated Carbon Nanofiber for Removal of Nickel(II) Ion from Aqueous Solution

The issue of heavy metal contamination has caused a great deal of concern among water quality experts today, as it contributes to water pollution. Activated carbon nanofibers (ACNFs) showed a significant ability in removing heavy metals from the wastewater. In this study, polyacrylonitrile (PAN) was blended and electrospun with an abundant and inexpensive biopolymer, lignin and a water soluble polymer, poly(ethylene glycol) (PEG), by using an electrospinning technique to form nanofibers. The electrospun nanofibers were then investigated as a precursor for the production of porous ACNFs to study the removal of nickel(II) ions by adsorption technique. PEG was added to act as a porogen and to create the porous structure of carbon nanofibers (CNFs). CNFs were prepared by thermal treatment of the electrospun nanofibers and followed by activation of CNFs by thermal and acid treatment on CNFs. Attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR) spectral analysis of the ACNFs showed a strong absorption peak of the C-O functional group, indicating the increase in the oxygenated compound. Field emission scanning electron microscopy (FESEM) images concluded that the ACNFs have more porous and compact fibers with a smaller fiber diameter of 263 ± 11 nm, while the CNFs are less compact and have slightly larger fiber diameter of 323 ± 6 nm. The adsorption study showed that the ACNFs possessed a much higher adsorption capacity of 18.09 mg/g compared with the CNFs, which the amount adsorbed was achieved only at 2.7 mg/g. The optimum adsorption conditions that gave the highest percentage of 60% for nickel(II) ions removal were 50 mg of adsorbent dosage, 100 ppm of nickel(II) solution, pH 3, and a contact time of 60 min. The study demonstrated that the fabrication of ACNFs from PAN/lignin/PEG electrospun nanofibers have potential as adsorbents for the removal of heavy metal contaminants.

Activation of electrospun carbon fibers: the effect of fiber diameter on CO2 and steam reaction kinetics

First, we present a fabrication process for electrospun carbon fiber mats with mean fiber diameters between 108 nm and 623 nm. The carbon fiber mats were produced by electrospinning of polyacrylonitrile (PAN) solutions and subsequent carbonization. The fiber mats feature small variations of their properties that are required for parameter studies. Second, we investigate the kinetics of steam and CO2 activation with three different activation temperatures and times. Both activation methods result in a surface area increase depending on activation temperature and time. Detailed analysis of the macroscopic properties burn-off, surface area, and conductivity reveals insights into the microscopic activation kinetics. The different fiber diameters of the carbon fiber mats enable the distinction of surface driven and bulk processes. Our results indicate, that CO2 activation kinetics are mass transport controlled, and that steam activation kinetics are reaction rate controlled. The turbostratic nature of PAN derived carbon and the distinct characteristics of the activation agents could explain the nonlinear behavior of the burn-off and surface area development.

Unveiling Carbon Ring Structure Formation Mechanisms in Polyacrylonitrile-Derived Carbon Fibers

As the demand for electric vehicles (EVs) and autonomous vehicles (AVs) rapidly grows, lower-cost, lighter, and stronger carbon fibers (CFs) are urgently needed to respond to consumers' call for greater EV traveling range and stronger safety structures for AVs. Converting polymeric precursors to CFs requires a complex set of thermochemical processes; a systematic understanding of each parameter in fiber conversion is still, to a large extent, lacking. Here, we demonstrate the effect of carbonization temperature on carbon ring structure formation by combining atomistic/microscale simulations and experimental validation. Experimental testing, as predicted by simulations, exhibited that the strength and ductility of PAN CFs decreased, whereas the Young's modulus increased with increasing carbonization temperature. Our simulations unveiled that high carbonization temperature accelerated the kinetics of graphitic phase nucleation and growth, leading to the decrease in strength and ductility but increase in modulus. The methodology presented herein using combined atomistic/microscale simulations and experimental validation lays a firm foundation for further innovation in CF manufacturing and low-cost alternative precursor development.

Analysis of Carbon-Based Microelectrodes for Neurochemical Sensing

The comprehensive microscopic, spectroscopic, and in vitro voltammetric analysis presented in this work, which builds on the well-studied properties of carbon-based materials, facilitates potential ways for improvement of carbon fiber microelectrodes (CFMs) for neuroscience applications. Investigations by both, scanning electron microscopy (SEM) and confocal Raman spectroscopy, confirm a higher degree of structural ordering for the fibers exposed to carbonization temperatures. An evident correlation is also identified between the extent of structural defects observed from SEM and Raman results with the CFM electrochemical performance for dopamine detection. To improve CFM physico-chemical surface stability and increase its mechanical resistance to the induced compressive stress during anticipated in vivo tissue penetration, successful coating of the carbon fiber with boron-doped diamond (BDD) is also performed and microspectroscopically analyzed here. The absence of spectral shifts of the diamond Raman vibrational signature verifies that the growth of an unstrained BDD thin film was achieved. Although more work needs to be done to identify optimal parameter values for improved BDD deposition, this study serves as a demonstration of foundational technology for the development of more sensitive electrochemical sensors, that may have been impractical previously for clinical applications, due to limitations in either safety or performance.

Thermal, Mechanical, and Microstructural Study of PBO Fiber during Carbonization

Poly(p-phenylene benzobisoxazole) (PBO) fiber shows fascinating properties including excellent mechanical performance, high crystallinity, and fairly good heat resistance as a kind of polymer fiber. Its properties make it a possible candidate as a precursor of carbon fiber. This paper mainly investigates the possibility of yielding carbon fiber from PBO by direct carbonization using a continuous process and multiple properties of yielded fiber treated under different heat treatment temperature (HTT). The results show that PBO fiber was able to sustain an HTT as high as 1400 °C under the inert atmosphere and that the shape of fiber was still preserved without failure. Using thermal gravimetric analysis (TGA) and TGA coupled with mass spectroscopy (TGA-MS), it was found that a significant mass loss procedure happened around 723.3 °C, along with the emission of various small molecules. The mechanical performance first suffered a decrease due to the rupture of the PBO structure and then slightly increased because of the generating of graphite crystallite based on the broken structure of PBO. It was observed that PBO’s microstructure transformed gradually to that of carbonaceous material, which could be the reason why the change of mechanical performance happened.

Simultaneous intercalated assembly of mesostructured hybrid carbon nanofiber/reduced graphene oxide and its use in electrochemical sensing

Polyacrylonitrile nonwovens intercalated with graphene oxide (GO) sheets were prepared by a simultaneous electrospinning-spray deposition system. These hybrid nonwovens were carbonized in a two-stage process to obtain a mesostructured hybrid carbon containing carbon nanofibers (CNF) and reduced GO sheets (CNF/RGO). During the carbonization process, the CNF act as spacers between the RGO layers to prevent their compactation and restacking resulting in a three-dimensional structure. The presence of RGO increases the electrical conductivity in the CNF/RGO material. The resulting hybrid carbon is nitrogen-doped as indicated by x-ray photoelectron spectroscopy and Fourier transformed infrared spectroscopy. This N-doped porous carbon was used to prepare electrodes with improved sensitivity for the electrochemical detection of L-cysteine.

The carbonization of polyacrylonitrile-derived electrospun carbon nanofibers studied by in situ transmission electron microscopy

The carbonization of polyacrylonitrile (PAN) nanofibers is observed in situ up to 1000 °C by transmission electron microscopy (TEM).

Porous Heat-Treated Polyacrylonitrile Scaffolds for Bone Tissue Engineering

Heat-treated polyacrylonitrile (HT-PAN), also referred to as black orlon (BO), is a promising carbon-based material used for applications in tissue engineering and regenerative medicine. To the best of our knowledge, no such complex bone morphology-mimicking three-dimensional (3D) BO structure has been reported to date. We report that BO can be easily made into 3D cryogel scaffolds with porous structures, using succinonitrile as a porogen. The cryogels possess a porous morphology, similar to bone tissue. The prepared scaffolds showed strong osteoconductive activity, providing excellent support for the adhesion, proliferation, and mitochondrial activity of human bone-derived cells. This effect was more apparent in scaffolds prepared from a matrix with a higher content of PAN (i.e., 10% rather than 5%). The scaffolds with 10% of PAN also showed enhanced mechanical properties, as revealed by higher compressive modulus and higher compressive strength. Therefore, these scaffolds have a robust potential for use in bone tissue engineering.

Ultra strong pyroprotein fibres with long-range ordering

Silks are protein-based natural structured materials with an unusual combination of high strength and elongation. Their unique microstructural features composed of hard β-sheet crystals aligned within a soft amorphous region lead to the robust properties of silks. Herein we report a large enhancement in the intrinsic properties of silk through the transformation of the basic building blocks into a poly-hexagonal carbon structure by a simple heat treatment with axial stretching. The carbon clusters originating from the β-sheet retain the preferred orientation along the fibre axis, resulting in a long-range-ordered graphitic structure by increasing heat-treatment temperatures and leading improvements in mechanical properties with a maximum strength and modulus up to ∼2.6 and ∼470 GPa, respectively, almost four and thirty times surpassing those of raw silk. Moreover, the formation of sp 2 carbon configurations induce a significant change in the electrical properties (e.g. an electrical conductivity up to 4.37 × 103 S cm-1).The mechanical properties of silk are determined by tight stacks of sheet-like peptide crystals distributed in amorphous regions. Here, the authors heat and stretch silk fibres to align these crystal into a long range ordered carbon structure and dramatically enhance the silk strength.