Polyacrylonitrile solution homogeneity study by dynamic shear rheology and the effect on the carbon fiber tensile strength

Poly(acrylonitrile‐co‐methacrylic acid) (PAN‐co‐MAA)/N,N‐dimethylformamide (DMF) solutions were prepared and dynamic shear rheology of these solutions were investigated. With increasing stirring time up to 72 h at 70°C, the polymer solution became less elastic (more liquid‐like) with a ～60% reduction in the zero‐shear viscosity. Relaxation spectra of the PAN‐co‐MAA/DMF solutions yield a decrease in relaxation time (disentanglement time, τ_d), corresponding to an about 8% decrease in viscosity average molecular weight. The log‐log plot of G′ (storage modulus) versus G″ (loss modulus) exhibited an increase in slope as a function of stirring time, suggesting that the molecular level solution homogeneity increased. In order to study the effect of solution homogeneity on the resulting carbon fiber tensile strength, multiple PAN‐co‐MAA/DMF solutions were prepared, and the precursor fibers were processed using gel‐spinning, followed by continuous stabilization and carbonization. The rheological properties of each solution were also measured and correlated with the tensile strength values of the carbon fibers. It was observed that with increasing the slope of the G′ versus G″ log‐log plot from 1.471 to 1.552, and reducing interfilament fiber friction during precursor fiber drawing through the addition of a fiber washing step prior to fiber drawing, the carbon fiber strength was improved (from 3.7 to 5.8 GPa). This suggests that along with precursor fiber manufacturing and carbonization, the solution homogeneity is also very important to obtain high strength carbon fiber. POLYM. ENG. SCI., 56:361–370, 2016. © 2016 Society of Plastics Engineers