Carbon fibers derived from wet‐spinning of equi‐component lignin/polyacrylonitrile blends

Equi‐component blends of polyacrylonitrile (PAN) and lignin, i.e., with a lignin content as large as 50 wt %, were successfully used as precursors to produce carbon fibers. Rheological measurements demonstrated that increasing lignin content in spinning solution reduced shear viscosity and normal stress, indicating a decrease of viscoelastic behavior. This was confirmed by Fourier transform infrared results that show no discernable chemical reaction or crosslinking between PAN and lignin in the solution. However, the resulting carbon fibers display a large I_D/I_G ratio (by Raman spectroscopy) indicating a larger disordered as compared to that from pure PAN. The macro‐voids in the lignin/PAN blend fibers typically generated during wet‐spinning were eliminated by adding lignin in the coagulant bath to counter‐balance the out‐diffusion of lignin. Carbon fibers resulting from lignin/PAN blends with 50 wt % lignin content displayed a tensile strength and modulus of 1.2 ± 0.1 and 130 ± 3 GPa, respectively, establishing that the equi‐component wet‐spun L/P‐based carbon fibers possessed tensile strength and modulus higher than 1 and 100 GPa. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45903.     

Fiber formation and properties of polyester/lignin blends

Thermotropic liquid crystalline polyesters with varied chemical structure are synthesized by melt transesterification polycondensation. They are employed as matrix for blends with lignin materials to obtain melt-spinnable precursors for carbon fibers. The lignin samples are carefully purified by fractionation, enzymatic removal of reducing sugars, and subsequent modification of the terminal OH groups. Effective melt blending is achieved with liquid-crystalline aromatic–aliphatic polyesters having melting ranges that match the softening temperature of the lignin fractions, which is necessary to prevent thermal decomposition of the lignin. Polyester/lignin blends are partially compatibilized, phase-separated materials. The polyester/lignin materials are melt-spun successfully. The fiber properties depend on the lignin purification process. X-ray scattering reveals that orientation in lignin-containing fibers is maintained. First experiments show that the fibers can be converted successfully to carbon fibers by thermal annealing procedures. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 48257.     

A new softening agent for melt spinning of softwood kraft lignin

Kraft lignin obtained from the pulping of wood is an interesting new precursor material for carbon fiber production because of its high carbon content and ready availability. However, continuous spinning of softwood kraft lignin (SKL) has been impossible because of its insufficient softening characteristics and neat hardwood kraft lignin (HKL) has required extensive pretreatments to enable fiber formation. Softwood kraft lignin permeate (SKLP) and hardwood kraft lignin permeate (HKLP), fractionated by membrane filtration, were continuously melt spun into fibers. To improve the spinnability of SKL and HKL, HKLP was added as a softening agent. SKL‐ and HKL‐based fibers were obtained by adding 3–98 wt % HKLP. A suitable temperature range for spinning was 20–85°C above the T_g of the lignin samples, and this range gave a flawless appearance according to the SEM analysis. Smooth, homogeneous fibers of SKLP, HKLP, and SKL with HKLP were successfully processed into solid carbon fibers. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Efficient solid‐phase synthesis of acetylated lignin and a comparison of the properties of different modified lignins

The chemical modification of lignin can greatly enhance its functionality and exploit its application areas. To avoid the difficulties of separation and environmental pollution in the traditional liquid‐phase method, we prepared acetylated lignin by a mechanical‐activation‐assisted solid‐phase synthesis (MASPS) technology with a customized stirring ball mill as a reactor and studied its structure and properties. Ultraviolet–visible analysis showed that the degree of esterification (DE) of the acetylated lignin produced by the MASPS technique was 77.59%, whereas the DEs of those produced by traditional liquid‐phase synthesis (LPS) and thermal solid‐phase synthesis (TSPS) were only 42.29 and 27.54%, respectively. Fourier transform infrared spectroscopy and NMR analyses indicated that both phenolic hydroxyls and aliphatic hydroxyls participated in the reaction, and the reactivity of the phenolic hydroxyls was higher than that of the aliphatic hydroxyl groups. The acetylation of aliphatic hydroxyl mainly happened at the γ of arylglycerol‐β‐aryl ether (β‐O‐4). Scanning electron microscopy analysis showed that the acetylated lignins prepared by MASPS and TSPS were irregular blocks with coarse surfaces and loose structures, whereas the lignin prepared by LPS consisted mostly of regular balls with a smooth surface and a compact structure. Differential scanning calorimetry and thermogravimetric analyses indicated that the glass‐transition temperatures and thermal stability of the acetylated lignin increased by orders with the processing techniques of MASPS, TSPS, and LPS. MASPS integrated the activation and reaction in the same equipment without the use of a solvent and showed advantages of a high efficiency, environmental protection, and easy operation. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44276.     

Tailoring the molecular and thermo–mechanical properties of kraft lignin by ultrafiltration

This study has shown that ultrafiltration allows the selective extraction from industrial black liquors of lignin fraction with specific thermo‐mechanical properties, which can be matched to the intended end uses. Ultrafiltration resulted in the efficient fractionation of kraft lignin according to its molecular weight, with an accumulation of sulfur‐containing compounds in the low‐molecular weight fractions. The obtained lignin samples had a varying quantities of functional groups, which correlated with their molecular weight with decreased molecular size, the lignin fractions had a higher amount of phenolic hydroxyl groups and fewer aliphatic hydroxyl groups. Depending on the molecular weight, glass‐transition temperatures (T_g) between 70 and 170°C were obtained for lignin samples isolated from the same batch of black liquor, a tendency confirmed by two independent methods, DSC, and dynamic rheology (DMA). The Fox–Flory equation adequately described the relationship between the number average molecular masses (M_n) and T_g's‐irrespective of the method applied. DMA showed that low‐molecular‐weight lignin exhibits a good flow behavior as well as high‐temperature crosslinking capability. Unfractionated and high molecular weight lignin (M_w >5 kDa), on the other hand, do not soften sufficiently and may require additional modifications for use in thermal processings where melt‐flow is required as the first step. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40799.     

Comparative characterization of degraded lignin polymer from the organosolv fractionation process with various catalysts and alcohols

Triploid poplar was fractionated using mild organosolv process, and detailed characteristic elucidation of the lignin obtained was performed to determine the effects of various chemicals (sodium hydroxide, triethylamine, and formic acid) and solvents (methanol, ethanol, n‐propanol, and n‐butanol). Both nondestructive techniques (e.g., NMR technology) and degradation methods (e.g., alkaline nitrobenzene oxidation) were performed to comparatively evaluate the structural degradation of lignin molecules. The addition of acidic and basic catalysts improved the purity of lignin by acid hydrolysis and the cleavage of the ester groups and other types of lignin–carbohydrate interactions formed by polyoses and lignin under the basic conditions. A certain amount of aryl alkyl ether linkages (β‐O‐4) was cleaved during the fractionation process, whereas other carbon–carbon linkages were resistant to degradation. The formation of new carbon–carbon bonds led to the lignin fraction with obviously higher molecular weight and thermal stability, resulting from the induced carbon cation under the acidic condition. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39673.     

Carbon Fibers Prepared from Melt Spun Peracylated Softwood Lignin: an Integrated Approach

Different softwood lignin O‐acyl derivatives, i.e., methacrylated, hexanoylated, benzoylated, methoxybenzoylated, and cinnamoylated lignin are synthesized and subjected to melt spinning. In the presence of spinning aids such as vanillin and ethylene glycol dimethacrylate, multifilament melt spinning is accomplished with spinning speeds up to 500 m min⁻¹, which allowed for realizing uniform precursor fibers 17 μm in diameter. Out of all acyl‐derivatives of softwood lignin investigated, cinnamoylated softwood lignin (CL) turned out to be superior in terms of processability. CL‐derived precursor fibers are oxidatively thermostabilized and then carbonized applying carbonization temperatures up to 2200 °C. Carbon fiber structure formation is followed in detail by wide‐angle X‐ray scattering and Raman spectroscopy. An orientation ≤53% and a d ₀₀₂ spacing of 0.353 nm is achieved. According to small angle X‐ray scattering, carbon fibers have a porosity of ≈38%. CL‐derived carbon fibers are also characterized in terms of mechanical properties. Tensile strengths up to 0.93 GPa (average 0.75 GPa) are obtained and follow Weibull statistics. Elastic moduli are ≤66.5 GPa (average 41.1 GPa).

     

Perfluorosulfonated ionomers membranes: Melt‐processing and characterization for ion exchange applications

Perflurosulfonated ionomers membranes with different ionic‐exchange capacity were successfully fabricated via melt‐extruding and casting of their –SO₂F precursors. A systematical investigation of the thermal stability, crystallinity, and rheological properties of the precursors was performed to secure their optimized processing conditions. The tensile properties of acid‐form membranes are found to increase with base‐hydrolysis time, where a tensile strength of 38.2 MPa is readily obtained after 24 h's base‐hydrolysis. The content of –SO₂F or –SO₃H containing side‐chains plays an important role in the thermal stability, rheological, and mechanical properties of the precursor or the acid‐form membranes. The strong ionic interactions, attributed to the –SO₃H groups, lead to decreased crystallinity and tensile strength for different IEC membranes. The acid‐form membranes exhibit good proton conductivity and low methanol crossover in comparison with reference Nafion membrane. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39944.     

Ecofriendly modification of acetosolv lignin from oil palm biomass for improvement of PMMA thermo‐oxidative properties

The environmentally friendly esterification of acetosolv lignin (AL), obtained from pressed oil palm mesocarp fibers, is described, for the improvement of thermo‐oxidative properties of poly(methyl methacrylate) (PMMA) films. Acetylation of AL was performed in ecofriendly conditions using acetic anhydride in the absence of catalysts. Acetylated acetosolv lignin (AAL) was successfully obtained in only 12 min with a solvent‐free and catalyst‐free microwave‐assisted procedure. Lignins were characterized by Fourier transform infrared spectroscopy, size exclusion chromatography, thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC), confirming the efficacy of the methodology employed. AL and AAL as fillers in different concentrations (1% and 5%) were added to PMMA films. The thermal and mechanical properties of the lignin‐incorporated films were analyzed by TGA, DSC, and dynamic mechanical analysis (DMA). The films incorporated with lignin and acetylated lignin presented initial degradation temperature (T_onset) and onset oxidative temperature (OOT) values higher than pure PMMA films, contributing thus to an enhancement of thermo‐oxidative stability of PMMA. The DMA analyses showed that incorporation of AL or AAL increased the storage modulus (E′) of PMMA films, but did not affect their glass‐transition temperatures (T_g). The results indicate the potential use of oil palm mesocarp lignin to enhance the thermo‐oxidative properties of PMMA without compromising its mechanical response. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45498.     

Influence of epichlorohydrin content on structure and properties of high‐ortho phenolic epoxy fibers

The high‐ortho phenolic epoxy fibers (HPEFs) were prepared by the crosslinking of heat‐meltable spun filaments derived from melt‐spinning of the novolac epoxy resins copolymerized among phenol, formaldehyde, and epichlorohydrin (ECH) in the presence of zinc acetate and sulfuric acid catalyst, and cured in a combined solution of formaldehyde and hydrochloric acid. The resulting fibers were heat‐treated in N₂ at elevated temperature. Infrared (IR) spectrometer, thermogravimetric analysis (TGA), scanning electron microscope (SEM), and electrical tensile strength apparatus were employed to characterize the change of functional groups, thermal performance, microstructure of fibers, and mechanical properties. The results show that the addition of ECH in the precursor resin can increase the content of long alkyl ether linkage, and gain the peak of thermal stability and mechanical strength. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43375.     

Synthesis,characterization, and curing behavior of carborane‐containing benzoxazine resins with excellent thermal and thermo‐oxidative stability

Two benzoxazine precursors bearing carborane moiety ( 1 and 2 ) were designed and synthesized successfully by the Mannich reaction of corresponding carborane bisphenol ( 3 and 4 ) with aniline and formaldehyde in 1,4‐dioxane. The obtained precursors were characterized by using multiple spectroscopic techniques including GPC, FTIR, ¹H NMR, ¹³C NMR, and ¹¹B NMR. Nonisothermal DSC studies showed that precursor 1 owned lower apparent activation energies (E_a) than 2 . The optimum curing processes of benzoxazine precursors were also obtained on the basis of DSC data. TGA analyses manifested that the incorporation of carborane moiety endowed the obtained benzoxazine resins (cured 1 and 2 ) with excellent thermal stability and unique thermo‐oxidative stability. The T_d data showed that the initial degradation of both cured 1 and 2 under nitrogen and air was postponed to some extent owing to the shielding effect of carborane moiety on adjacent organic fragments. At higher temperature three‐dimensional polymer networks with B‐O‐B and B–C linkages were formed as chars by the reaction of carborane cage with atmospheric moisture, degradation products such as phenolic hydroxyl, and oxygen (under air). Under nitrogen this network hindered the motion of radicals formed at elevated temperature and thus inhibited further polymer degradation processes. While under air, the formed boron‐rich networks could hardly be further oxidized into carbon dioxide so that the carborane‐containing benzoxazine resins also showed very high char yields. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43488.     

Effect of nanofillers as reinforcement agents for lignin composite fibers

Biobased nanocomposites and composite fibers were prepared from organosolv lignin/organoclay mixtures by mechanical mixing and subsequent melt intercalation. Two organically‐modified montmorillonite (MMT) clays with different ammonium cations were used. The effect of organoclay varying from 1 to 10 wt % on the mechanical and thermal properties of the nanocomposites was studied. Thermal analysis revealed an increased in T_g for the nanocomposites as compared with the original organosolv lignin. For both organoclays, lignin intercalation into the silicate layers was observed using X‐ray diffraction (XRD). The intercalated hybrids exhibited a substantial increase in tensile strength and melt processability. In the case of organoclay Cloisite 30B, X‐ray analysis indicates the possibility of complete exfoliation at 1 wt % organoclay loading. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Characterization of soda hardwood lignin and the formation of lignin fibers by melt spinning

Lignin fibers were developed from a commercial available soda hardwood lignin (SHL) with a melt‐spinning approach. SHL showed spinnability to form the fine fibers when poly(ethylene oxide) was used as a plasticizer with lignin. The thermal properties of lignin provided valuable information to assist the processing steps of the lignin fiber formation. The guaiacyl/syringyl ratio in SHL was determined by ³¹P‐NMR because it had great influence on the thermal mobility of lignin. A suitable temperature profile for the melt spinning was predicted through rheological studies of lignin. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Thermal treatment of pyrolytic lignin and polyethylene terephthalate toward carbon fiber production

In this work, pyrolytic lignin (PL) was thermally co-treated with polyethylene terephthalate (PET) to produce carbon fiber precursor. The produced PL-PET precursors were thoroughly characterized and analyzed, and then being processed into carbon fiber. It was found that a novel precursor, rather than their physical blending, was formed by the thermal co-treatment, indicating there were strong interactions between PL and PET. The novel PL-PET precursors had enhanced thermal properties and rheological characteristics, therefore are more suitable for processing into better carbon fibers based on melt-spinning method. In this study, the precursor fibers derived from the co-treatment of PL and 5% PET were also stretched under tension during stabilization step to reduce the fiber diameter and improve molecular orientation. The resulting carbon fibers with an average diameter of 12.6 μm had the tensile strength of up to 1220 MPa. This work demonstrated that PET could be used to improve the processability and quality of lignin-based carbon fiber when it is chemically bonded with lignin-based precursor. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48843.     

Compatibility improvement of poly(lactic acid)/thermoplastic starch blown films using acetylated starch

The present research aims to improve the compatibility between relatively hydrophobic poly(lactic acid) (PLA) and hydrophilic thermoplastic starch (TPS) and the properties of the PLA/TPS blends by replacing TPS from native cassava starch (TPSN) with TPS from acetylated starch (TPSA). The effects of the degree of acetylation (DA) of acetylated starch, that is, 0.021, 0.031, and 0.074, on the morphological characteristics and properties of PLA/TPS blend are investigated. The melt blends of PLA and TPS with a weight proportion of PLA:TPS of 50:50 are fabricated and then blown into films. Scanning electron microscopy confirms the dispersion of TPS phase in the PLA matrix. Better dispersion and smaller size of the TPS phase are observed for the PLA/TPSA blend films with low DA of acetylated starch, resulting in improved tensile and barrier properties and increased storage modulus, thermal stability, and T_g, T_cc, and T_m of PLA. Elongation at break of the PLA/TPSA blend increases up to 57%, whereas its water vapor permeability and oxygen permeability decrease about 15%. The obtained PLA/TPSA blend films have the potential to be applied as biodegradable flexible packaging.     

Characteristics of wet‐spun and thermally treated poly acrylonitrile fibers

The performance of carbon fibers depends on the quality of the precursor and the conditions of the thermal treatment. In detail, for a PAN precursor fiber the viscosity of a spinning dope and the draw ratio during the spinning process needs to be considered. Through wet spinning, different types of PAN precursor fibers with defined spinning parameters, including solid content, solvent content in a bath, and especially draw ratio resulting in defined cross section diameters, were fabricated and analyzed with tensile tests, density investigations, SEM, TGA‐MS, FTIR, and XRD. The results show that the mechanical properties of the fibers correlate to crystallinity. The cross section diameter is strongly related to the morphology of the fibers after thermal treatment. By extending the postdrawing of PAN fibers high tenacities were obtained at the cost of the cross section shape. In addition, TGA measurements reveal trapped residues of the wet spinning process as well as show several chemical reactions takes place at the same time at different temperatures. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43698.     

Alternating copolymerization and terpolymerization of vinyl‐substituted phenolic antioxidants with propene and carbon monoxide by a palladium(II)‐based catalyst: polyketones containing intramolecular stabilizers

The copolymerization and terpolymerization reactions of the vinyl‐substituted phenolic stabilizers, 6‐tert‐butyl‐2‐(1,1‐dimethylhept‐6‐enyl)‐4‐methylphenol, o‐allylphenol, 4‐methylstyrene‐2,6‐di‐tert‐butylphenol and 2,6‐di‐tert‐butyl‐4‐allylphenol, with propene and carbon monoxide, by using the solvent‐stabilized palladium(II ) phosphine complex [Pd(dppp)(NCCH₃)₂](BF₄)₂ (dppp, 1,3‐bis(diphenylphosphino)propane) as a catalyst precursor and methanol as a co‐catalyst, is described. The influence of functional α‐olefins/CO units, distributed statistically along the propene/carbon monoxide (P/CO) copolymer backbone, on the molecular weight, glass transition temperature (T_g), elastic behavior and stability of the high‐molecular‐weight P/CO copolymer has been investigated. Loss of both elasticity and transparency were observed upon incorporating o‐allylphenol as a termonomer. The terpolymers, which contain phenolic stabilizers, were shown to be more stable when compared to the stabilizer‐free polyketones. In contrast to the propene/carbon monoxide copolymer, no degradation was observed for the 2,6‐di‐tert‐butyl‐4‐allylphenol/P/CO terpolymer; instead, the molar masses increased. Copyright © 2004 Society of Chemical Industry     

Preparation and characterization of lignin‐layered double hydroxide/styrene‐butadiene rubber composites

Lignin‐layered double hydroxide (lignin‐LDH) complex was synthesized by in situ method, and then styrene‐butadiene rubber (SBR)/lignin‐LDH composites were prepared by the melt compounding method. X‐ray diffraction analysis showed that crystal lignin‐LDH was successfully obtained and transmission electron microscopy analysis showed well dispersion of lignin‐LDH in SBR matrix. The tensile strength, elongation at break, 300% modulus and hardness of lignin‐LDH/SBR were significantly improved compared to LDH/SBR composites. Thermogravimetric analysis indicated that the thermal degradation temperature of the lignin‐LDH/SBR at 10% weight loss (T₁₀) decreased whereas 50% weight loss (T₅₀) was much higher than that of pristine LDH/SBR due to barrier property of the well dispersed Lignin‐LDH in SBR matrix. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 1308‐1312, 2013     

Lignin valorization by forming thermally stimulated shape memory copolymeric elastomers—Partially crystalline hyperbranched polymer as crosslinks

Lignin based thermal‐responsive elastomers were produced by a melt polycondensation reaction with a long alkyl chain hyperbranched poly(ester‐amine‐amide) (B₃‐A₂‐CB₃¹). The effect of lignin content on elastomers properties was investigated. The thermal and mechanical properties of the copolymers were characterized by DMA, DSC, and TGA. The morphology of the copolymer was examined by SEM. Tensile properties were dominated by HBP <25% lignin content while lignin dominated >25% content. The copolymers glass transition temperature (T_g) increased with lignin content. The elastomer with 30% lignin content demonstrated optimal mechanical properties (tensile strength 5.3 MPa, Young's modulus 8.9 MPa, strain at break 301%, and toughness 1.03 GPa). Thermally stimulated dual shape memory effects (SME) of the copolymers were quantified by cyclic thermomechanical tests. The transition temperature (T_trans) of the polymer was able to be controlled (room to body temperature) by varying the amount of lignin added which broadens the range to medical applications. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 41103.     

Enhanced oil resistance and mechanical properties of nitrile butadiene rubber/lignin composites modified by epoxy resin

This is probably the first report on developing nitrile butadiene rubber (NBR) composites with enhanced performance s via lignin bridged epoxy resin in the rubber matrix. NBR/lignin masterbatch has been prepared through latex‐compounding method, and then epoxy resin (F51) was added in the NBR/lignin compounds by the melt compounding method. Lignin‐epoxy resin networks were synthesized in situ during the curing process of rubber compounds through epoxide?hydroxyl reactions. Compared with lignin filler, lignin‐F51 networks showed an improved oil resistance ability and led to increased mechanical properties, crosslinking density, and thermal stability of the rubber composites. This method provides a new insight into the fabrication of novel interpenetrating polymer networks in rubber composites and enlarges the potential applications of lignin in high performance rubber composites. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 42922.