Non-Coagulant Spinning of High-Strength Fibers from Homopolymer Polyacrylonitrile Synthesized via Anionic Polymerisation

The rheological properties, spinnability, and thermal-oxidative stabilization of high-molecular-weight linear polyacrylonitrile (PAN) homopolymers (molecular weights Mη = 90-500 kg/mol), synthesized via a novel metal-free anionic polymerization method, were investigated to reduce coagulant use, enable solvent recycling, and increase the carbon yield of the resulting carbon fibers. This approach enabled the application of the mechanotropic (non-coagulating) spinning method for homopolymer PAN solutions in a wide range of molecular weights and demonstrated the possibility of achieving a high degree of fiber orientation and reasonable mechanical properties. Rheological analysis revealed a significant increase in solution elasticity (G') with increasing molecular weight, facilitating the choice of optimal deformation rates for effective chain stretching prior to strain-induced phase separation during the eco-friendly spinning of concentrated solutions without using coagulation baths. The possibility of collecting ~80 wt% of the solvent at the first stage of spinning from the as-spun fibers was shown. Transparent, defect-free fibers with a tensile strength of up to 800 MPa and elongation at break of about 20% were spun. Thermal treatment up to 1500 °C yielded carbon fibers with a carbon residue of ~50 wt%, in contrast to ~35 wt% for industrial radically polymerized PAN carbonized under the same conditions.

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.

Analysis of Terpolymerization Systems for the Development of Carbon Fiber Precursors of PAN

The thermal stabilization of polyacrylonitrile fibers (FPAN) is one of the most important steps in the production of carbon fibers (CFs). In this paper, new precursor polymers from PAN have been synthesized with different chemical characteristics using a solution polymerization, and FPAN was obtained using an unconventional wet spinning system in the drying and collapsing steps. The effect of different operation conditions, comonomers, and termonomers on the properties of precursor polymers, polymerization reactions, mechanical properties, structural characteristics, and stabilization of the FPAN was studied and analyzed. FTIR and optical microscopy were used to analyze structural changes of FPAN in the thermal stabilization. The impact of the chemical composition of the precursor polymers on the physicochemical characteristics of FPAN and their behavior in the thermal stabilization process were evaluated. In particular, itaconic acid termonomer improved the tensile strength of the fibers from 8.07 to 16.87 cN/dtex, and the extent stabilization increased from 1.81 to 4.6. FTIR indicated that the reaction of stabilization of the terpolymer developed was initiated at a lower temperature compared to that of a commercial precursor polymer.