WO2016199060A1 - A fiber and a process for the manufacture thereof - Google Patents
A fiber and a process for the manufacture thereof Download PDFInfo
- Publication number
- WO2016199060A1 WO2016199060A1 PCT/IB2016/053401 IB2016053401W WO2016199060A1 WO 2016199060 A1 WO2016199060 A1 WO 2016199060A1 IB 2016053401 W IB2016053401 W IB 2016053401W WO 2016199060 A1 WO2016199060 A1 WO 2016199060A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- carbon fiber
- lignin
- cellulose
- fiber
- highly oriented
- Prior art date
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 57
- 238000000034 method Methods 0.000 title claims abstract description 57
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 34
- 230000008569 process Effects 0.000 title description 12
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 134
- 239000004917 carbon fiber Substances 0.000 claims abstract description 134
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 102
- 229920005610 lignin Polymers 0.000 claims description 78
- 229920002678 cellulose Polymers 0.000 claims description 70
- 239000001913 cellulose Substances 0.000 claims description 70
- 239000002243 precursor Substances 0.000 claims description 67
- 230000006641 stabilisation Effects 0.000 claims description 36
- 238000011105 stabilization Methods 0.000 claims description 36
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 21
- 229910052799 carbon Inorganic materials 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 17
- 238000009656 pre-carbonization Methods 0.000 claims description 17
- 238000003763 carbonization Methods 0.000 claims description 15
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 10
- 238000005087 graphitization Methods 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 9
- 238000009987 spinning Methods 0.000 claims description 7
- 239000011261 inert gas Substances 0.000 claims description 5
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 4
- 238000004090 dissolution Methods 0.000 claims description 3
- 239000003733 fiber-reinforced composite Substances 0.000 claims description 2
- 235000010980 cellulose Nutrition 0.000 description 63
- 238000006243 chemical reaction Methods 0.000 description 13
- 238000004537 pulping Methods 0.000 description 11
- 238000004736 wide-angle X-ray diffraction Methods 0.000 description 8
- 239000000203 mixture Substances 0.000 description 7
- 229920001131 Pulp (paper) Polymers 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 229920003043 Cellulose fiber Polymers 0.000 description 4
- 241000196324 Embryophyta Species 0.000 description 4
- 229920001046 Nanocellulose Polymers 0.000 description 4
- 239000002655 kraft paper Substances 0.000 description 4
- 239000011122 softwood Substances 0.000 description 4
- 210000001170 unmyelinated nerve fiber Anatomy 0.000 description 4
- 239000002028 Biomass Substances 0.000 description 3
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 3
- 230000002860 competitive effect Effects 0.000 description 3
- 239000011121 hardwood Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 238000006467 substitution reaction Methods 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 2
- 229920000875 Dissolving pulp Polymers 0.000 description 2
- 229920000168 Microcrystalline cellulose Polymers 0.000 description 2
- 241000218657 Picea Species 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000007833 carbon precursor Substances 0.000 description 2
- 230000015271 coagulation Effects 0.000 description 2
- 238000005345 coagulation Methods 0.000 description 2
- -1 hydroxyl propyl Chemical group 0.000 description 2
- 235000019813 microcrystalline cellulose Nutrition 0.000 description 2
- 239000008108 microcrystalline cellulose Substances 0.000 description 2
- 229940016286 microcrystalline cellulose Drugs 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 239000004626 polylactic acid Substances 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000002166 wet spinning Methods 0.000 description 2
- WAZPLXZGZWWXDQ-UHFFFAOYSA-N 4-methyl-4-oxidomorpholin-4-ium;hydrate Chemical compound O.C[N+]1([O-])CCOCC1 WAZPLXZGZWWXDQ-UHFFFAOYSA-N 0.000 description 1
- 102100031260 Acyl-coenzyme A thioesterase THEM4 Human genes 0.000 description 1
- 241000609240 Ambelania acida Species 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- 241001330002 Bambuseae Species 0.000 description 1
- 235000018185 Betula X alpestris Nutrition 0.000 description 1
- 235000018212 Betula X uliginosa Nutrition 0.000 description 1
- KXDHJXZQYSOELW-UHFFFAOYSA-M Carbamate Chemical compound NC([O-])=O KXDHJXZQYSOELW-UHFFFAOYSA-M 0.000 description 1
- 229920002488 Hemicellulose Polymers 0.000 description 1
- 101000638510 Homo sapiens Acyl-coenzyme A thioesterase THEM4 Proteins 0.000 description 1
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 1
- 229920001732 Lignosulfonate Polymers 0.000 description 1
- 229920000433 Lyocell Polymers 0.000 description 1
- LFTLOKWAGJYHHR-UHFFFAOYSA-N N-methylmorpholine N-oxide Chemical compound CN1(=O)CCOCC1 LFTLOKWAGJYHHR-UHFFFAOYSA-N 0.000 description 1
- 241001520808 Panicum virgatum Species 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000001580 bacterial effect Effects 0.000 description 1
- 239000010905 bagasse Substances 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- 239000011176 biofiber Substances 0.000 description 1
- 150000001720 carbohydrates Chemical class 0.000 description 1
- 235000014633 carbohydrates Nutrition 0.000 description 1
- 229920003086 cellulose ether Polymers 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000011437 continuous method Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000010411 cooking Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 238000007380 fibre production Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- TWNIBLMWSKIRAT-VFUOTHLCSA-N levoglucosan Chemical compound O[C@@H]1[C@@H](O)[C@H](O)[C@H]2CO[C@@H]1O2 TWNIBLMWSKIRAT-VFUOTHLCSA-N 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 125000002560 nitrile group Chemical group 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000008194 pharmaceutical composition Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000002633 protecting effect Effects 0.000 description 1
- 239000003265 pulping liquor Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000007363 ring formation reaction Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical compound [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- AVWRKZWQTYIKIY-UHFFFAOYSA-N urea-1-carboxylic acid Chemical compound NC(=O)NC(O)=O AVWRKZWQTYIKIY-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/05—Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
- C08B16/00—Regeneration of cellulose
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/02—Cellulose; Modified cellulose
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L97/00—Compositions of lignin-containing materials
- C08L97/005—Lignin
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected
- D01D10/02—Heat treatment
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/06—Wet spinning methods
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
- D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
- D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
- D01F9/16—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from products of vegetable origin or derivatives thereof, e.g. from cellulose acetate
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
- D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
- D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
- D01F9/16—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from products of vegetable origin or derivatives thereof, e.g. from cellulose acetate
- D01F9/17—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from products of vegetable origin or derivatives thereof, e.g. from cellulose acetate from lignin
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
- D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
- D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
- D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
- D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
- D02J1/221—Preliminary treatments
Definitions
- the present invention relates to a process for the manufacture of endless filament yarns called hereafter thermally stabilized, non-sticky and stretchable fibers, based on a precursor containing cellulose and lignin. Those fibers are suitable for making intermediate carbon fibers. These intermediate carbon fibers may be provided with an oriented structure, through using additional steps obtained by, what is thought to be, plastic deformation of the said precursor in a temperature range of from 200 °C to 1300 °C. The oriented structure obtained may be maintained during the subsequent carbonization process by using carbonization temperatures from 900 °C to 3000 °C for producing a final carbon fiber.
- Final carbon fibers based on highly oriented intermediate carbon fibers are characterized by
- the present invention also provides a highly oriented intermediate carbon fiber and also a highly oriented carbon fiber.
- the ideal requirements for a carbon fiber precursor are that it should be easily converted to carbon fiber, give a high carbon yield and allowed to be processed economically.
- Other important requirements for precursor materials are spinnability i.e. the ability to form filaments, stretchability, i.e. the ability to stretch and align its molecular structure along the fiber direction and the ability to form a thermoset in the stabilization process i.e. to become infusible so that the individual filaments do not stick together.
- the sticking of filaments must be avoided because it causes surface defects and unequal diffusion during thermal conversion to carbon fiber leading to poor mechanical performance .
- the material must furthermore be able to maintain its stretched structure during thermal conversion to form linearly oriented graphite structures in the carbon fiber. Only few materials exhibit this combination of requirements.
- PAN poly-acrylonitrile
- Precursors from melt-spun lignin and lignin derivatives and hybrid precursors from solvent-spun PAN and lignin are two important technology platforms under development.
- Typical target properties for these kinds of carbon fibers are 170 GPa tensile modulus and 1.7 GPa tensile strength [2], i.e. lower than the properties of commercial PAN-based carbon fibers.
- Lignin is a polyaromatic polyol and constitutes, after cellulose, the second largest material component in wood and other lignocellulosic plants. The amount of carbon in lignin is relatively high, approx.
- lignin is regarded as a promising raw material for carbon fiber with respect to giving a high carbon yield.
- chemical pulping cellulosic fibers are separated from softwoods, hardwoods, and annual plant biomass, for further processing to paper, board, tissue products and man-made cellulose fibers.
- Kraft pulping is the dominant chemical pulping process.
- Other processes include soda pulping, sulfite pulping (which gives lignosulfonates ) and the organosolv process.
- alkaline pulping i.e. kraft and soda pulping
- large quantities of lignin become
- the alkaline pulping liquor known as black liquor
- black liquor a highly alkaline complex mixture containing used cooking chemicals, solubilized wood lignin, carbohydrates and organic acids.
- the lignin can be further processed to energy by combustion of the partly evaporated black liquor or, alternatively, be isolated, for example by precipitation using acid.
- precipitated lignin is determined by the type of biomass used and the pulping method. Lignin may be melt-spun to filaments but such lignin fibers may have several
- Lignin fibers easily melt during thermal conversion to carbon fiber.
- thermoset material i.e. an infusible non-sticky stabilized fiber for conversion into the final carbon fiber
- the lignin precursor has to be stabilized at extremely low heating rates. Values are reported in the range between 0.05 °C/min [3] up to 0.5 °C/min [4] . Consequently, the total residence times during stabilization for reaching the final stabilization
- WO 2012003070 describes a method for the manufacture of dopes containing poly-acrylonitrile (PAN) and lignin for the production of carbon fiber precursors via solvent spinning.
- PAN poly-acrylonitrile
- Lignin precursor fibers are characterized by an extremely brittle behavior and low mechanical properties (30 to 35 MPa tensile strength and 0.5 to 1 % elongations-at- break) throughout the whole temperature range between room temperature and 300 °C [6] .
- the literature does not report on a successful continuous conversion of lignin precursors to carbon fiber, only batch-wise conversion. The most probable explanation is that lignin fibers cannot withstand the mechanical stresses during continuous production caused by fiber transportation (via rollers), stretching and winding/unwinding. Cellulose-precursors, by contrast, have higher mechanical performance. The subsequent stabilization of the cellulose precursor, however, is associated with a very high yield loss and depolymeri zation .
- Stretch graphitization at temperatures between 2500 °C and 3000 °C must be applied in order to form oriented graphite domains for high mechanical performance [8] which causes a poor material yield (typically 10-20%) .
- the high temperatures needed and the poor material yield lead to high production costs for cellulose-based carbon fiber .
- Cellulose is a lower cost raw material than PAN and, in contrast to PAN, a renewable raw material.
- PAN a renewable raw material.
- the high yield loss and the high energy input needed during stretch- graphitization of cellulose make the manufacture of
- the present invention addresses the problems of carbon fiber production that are related to stretching and
- the problem to be solved is to convert cellulose-based precursor cost efficiently to high-performing carbon fiber or precursors thereof. It has now surprisingly been found, that by using a certain method, involving the addition of lignin or lignin derivate to the cellulose, a stabilization step and a stretch-pre-carbonization step, a highly-oriented cellulose-based precursor cost efficiently to high-performing carbon fiber or precursors thereof. It has now surprisingly been found, that by using a certain method, involving the addition of lignin or lignin derivate to the cellulose, a stabilization step and a stretch-pre-carbonization step, a highly-oriented
- Said intermediate carbon fiber is provided with such properties that alleviate or even solve one or more of the problems connected with the manufacturing of carbon fibers from cellulose. Said intermediate carbon fiber can be converted to a highly- oriented carbon fiber. Furthermore, said carbon fiber is completely based upon renewable resources.
- the present invention thus solves one or more of the above problems, by providing according to a first aspect a highly oriented intermediate carbon fiber having a
- Modulus i.e. elastic modulus, (of Intermediate Carbon- fiber) of from about 40 to about 60 GPa.
- Said intermediate carbon fiber may be made using a method as set out in the fourth aspect as set out below.
- a highly oriented carbon fiber having an elastic modulus of at least about 100 GPa, and preferably also a tensile strength of at least about 1.1 GPa.
- Said carbon fiber may be made using a method as set out in the eighth aspect as set out below.
- Also provided according to a third aspect of the invention is a method for manufacturing a thermally stabilized, non-sticky and stretchable fiber, suitable for making an intermediate carbon fiber, comprising the
- thermally stabilized, non-sticky and stretchable fiber .
- Also provided according to a fourth aspect of the invention is a method for manufacturing a highly oriented intermediate carbon fiber involving the above steps and also comprising a subsequent step:
- Also provided according to a sixth aspect of the invention is a highly oriented intermediate carbon fiber obtainable by the method according to the fourth aspect.
- Also provided according to a seventh aspect of the invention is use of the fibers according to the first, fifth and sixth aspect for the manufacture of carbon fibers.
- Also provided according to an eighth aspect is a method for manufacturing a highly oriented carbon fiber comprising the following steps
- Also provided according to a ninth aspect is a highly oriented carbon fiber obtainable by the method according to the eighth aspect.
- Also provided according to an tenth aspect is use of the highly oriented carbon fiber according to the second or ninth aspect in the manufacture of carbon fiber- reinforced composites for applications such as
- lignin embraces any lignin which may be used for making a carbon fiber or precursors thereof.
- examples on said lignin are, but are not limited to softwood lignin, hardwood lignin, lignin from one-year plants or lignins obtained through different pulping methods such as,
- the lignin may e.g. be isolated by using the process disclosed in EP 1794363.
- the term "lignin” also encompasses native lignin in biomass.
- cellulose embraces any type of cellulose, such as cellulose fibers and cellulose materials.
- the cellulose may also be a microfibrillated cellulose (MFC) .
- MFC microfibrillated cellulose
- the cellulose may be bleached or unbleached.
- the cellulose may also be crystalline cellulose, MCC (microcrystalline cellulose); it may have a high purity due to its potential use in pharmaceutical compositions or other medical uses .
- the cellulose may be bacterial nanocellulose (BNC) or
- nanocrystalline cellulose NCC
- the cellulose may be man-made synthetic polymer fibers and fibers made from dissolving pulp.
- the cellulose may have its origin from of a pulp, which may be chemical pulp, mechanical pulp,
- thermomechanical pulp or chemi ( thermo ) mechanical pulp CMP or CTMP
- the pulp may consist of pulp from hardwood, softwood or both types.
- the pulp may e.g. contain a mixture of pine and spruce or a mixture of birch and spruce.
- the chemical pulps that may be used in the present invention include all types of chemical wood-based pulps, such as bleached, half- bleached and unbleached sulphite, kraft and soda pulps, and mixtures of these.
- the pulp may be a dissolving pulp.
- the pulp may also comprise textile fibers.
- the pulp may also be based on one-year plants (e.g. bagasse, bamboo, swi tchgrass ) .
- the pulp may also be nanopulp comprised of nanocellulose fibers. Also combinations of said pulp types are possible in the context of the present invention.
- the pulp may also contain synthetic fibers or biofibers such as PLA (Poly- lactic acid) . Said cellulose may be converted into a
- cellulose derivative embraces any type of fiber- forming cellulose derivate, in particular 1) cellulose carbamate, 2) cellulose ethers with low degree of substitution, in particular methyl (CMC) or ethyl
- the solution spinning of the dope to a precursor material of step d) in the third aspect of the present invention may be performed via techniques known to a person skilled in the art such as via wet spinning or dry jet-wet spinning.
- the stabilization is performed at a temperature from about 100 to about 450 °C, preferably from about 200 to about 350 °C, most preferred from about 220 to about 300 °C, wherein the stabilization is done at a residence time of from 10 to 180 minutes, preferably from 20 to 80 minutes .
- containing cellulose and/or cellulose derivative and lignin and/or lignin derivative has a content of lignin and/or lignin derivative at a maximum amount of 99 wt% .
- lignin or lignin derivative contains from about 1% to 99 % lignin or lignin derivative, preferably from 10% to 60 % lignin or lignin derivative, most preferred from 15% to 55 % lignin or lignin derivative.
- heating rates up to 200 °C/min are applied in the stabilization step.
- the molecular orientation in the carbon fiber is realized by stretching the fiber during the stretch-pre-carboni zation up to 10-fold at a temperature below 1300 °C, preferably below 1100 °C, most preferred below 1000 °C.
- the pre-stretch carbonization is carried out at temperatures from about 200 to about 1300 °C, preferably from 250 to 1100 °C, most preferred from 300 to 900 °C.
- the stretch-pre-carbonization is performed during a residence time from 1 to 90 minutes, preferably from 3 to 60 minutes and most preferred from 5 to 30 minutes .
- said stretching is carried out at elongations between 10% and 1000%, preferably between 10% and 500%, most preferred between 10% and 300%.
- the present invention relates to the manufacture of highly oriented carbon fibers from cellulose precursor fibers and avoids the two significant drawbacks of the classical method, viz. the costly stretch graphitization and the low carbon yield.
- this is accomplished by mixing lignin or lignin derivatives with the cellulose or cellulose derivative.
- the present invention also relates to a method for the continuous and cost-efficient production of thermally stabilized, non-sticky and stretchable endless multifilament yarns from precursors containing lignin and cellulose.
- the said lignin-cellulose precursor yarns can withstand fast heating rates during stabilization without sticking of the individual filaments and without melting. Surprisingly, residence times of 60 minutes orshorter for the entire conversion process from precursor to carbon fiber may be realized.
- the yarn treated in that way has a tensile strength in the range of 150-200 MPa and elongations at break between 3 and 5 % i.e. more than three times higher than the values reported for lignin precursors ( [6] , see table 1) .
- the fibers stabilized according to this method are strong enough to withstand the mechanical stresses during the subsequent process steps such as winding/unwinding, fiber transportation (via rollers) and stretching, without difficulties, like stabilized PAN fibers. This is a prerequisite for enabling a cost-efficient and continuous manufacturing process from precursor to final carbon fiber.
- the said stabilized fiber based on a precursor from cellulose and lignin has much higher tensile strength and elongation-at-break than a stabilized precursor fiber from either lignin or cellulose (see table 1) .
- said stabilized fiber can be stretched in a subsequent stretch-pre-carbonization step.
- the thermally stabilized fiber manufactured according to the method described in this invention is suited for the subsequent conversion to carbon fibers with tensile strengths and moduli above 1 GPa and 100 GPa, respectively.
- Literature reports carbon yields of about 40% for the manufacture of carbon fiber from lignin-based precursor
- Carbon yield is increased from 10% for lignin-free cellulose systems (see example 2) to 40% for a system containing 50% cellulose and 50% lignin (see example 1) . This is thought to be attributed to a protecting effect of the lignin component on the cellulose that decreases the thermal decomposition of cellulose .
- a stretch-induced orientation which is crucial for attaining good mechanical properties of the carbon fiber, can surprisingly already be realized at temperatures as low as 200 to 1300 °C, in contrast to 2500- 3000 °C for the lignin-free cellulose system. This is attributed to a plasticizing effect of the lignin component on cellulose.
- An intermediate carbon fiber may thus be obtained with a carbon content of ⁇ 90 mol% and a high degree of molecular orientation.
- a subsequent carbonization step can be performed energy efficiently at moderate temperatures such as from 1200 °C to 1800 °C resulting in a final carbon fiber with carbon content > 95 % .
- the orientation generated during the formation of the intermediate carbon fiber is maintained in the final carbon fiber.
- Figure 1 discloses a processing line for producing highly oriented intermediate carbon fibers.
- Figure 2 discloses WAXS flat film photographs of intermediate carbon fibers examples 8-12, stretched in a range between -17% (free shrinkage) and 150% elongation.
- the data shows an increase in preferred orientation of the graphite-like structure along the fiber axis with increasing stretch.
- Figure 3 shows a WAXS flat film photograph of intermediate C- fiber produced with -17% stretch (example 8) and that of the corresponding carbon fiber (example 13)
- Figure 4 shows a WAXS flat film photograph of intermediate C-fiber produced with 100% stretch (example 11) and that of the corresponding carbon fiber (example 14) . From figures 3 and 4 it can be concluded that the degree of orientation in the final carbon fiber corresponds to the degree of orientation in the preceding intermediate carbon fiber, with the difference that the arc position is now at the angle characteristic for graphitic reflections .
- a multifilament yarn containing cellulose and lignin produced according to the method described in WO2012156441A1 was used as precursor.
- the said precursor was thermally stabilized in a stabilization step to render it infusible according to the method described in the present invention.
- the precursor was thus heated to temperatures between 200 and 300 °C at heating rates of up to 200 °C/min at residence times between 20 to 80 minutes.
- the resulting stabilized filament yarn is characterized in that it is a thermoset, i.e. not meltable and that its filaments do not stick together.
- the stabilized filament yarn is characterized in that it is strong enough to withstand the mechanical stresses induced during the subsequent process steps involved during continuous conversion to carbon fiber, such as winding/unwinding, yarn transportation and stretching.
- the said stabilized fiber based on a precursor from cellulose and lignin has much higher tensile strength and elongation-at-break than a stabilized precursor fiber from either lignin or cellulose (see table 1) .
- the stabilized carbon fiber according to this invention is stretchable.
- the stabilization was performed in a continuous mode by transporting the multifilament yarn through a tubular furnace with orifices at both ends. An appropriate mechanical tension applied at the ends of the furnace that prevents the yarn from contact with the surface. The yarn passes freely through the furnace with high process stability.
- the stabilized multifilament yarn was transformed in the subsequent step, hereafter called stretch-pre-carboni zation, into the so-called highly oriented intermediate carbon fiber at temperatures between 300 and 900 °C in an inert gas such as nitrogen with residence times between 5 and 30 minutes.
- the stabilized cellulose-containing filament yarn can be stretched appreciably by applying an appropriate fiber tension.
- the degree of stretch correlates with the degree of orientation in the resulting intermediate carbon fiber (see figure 2) .
- the ability of the yarn to be stretched, i.e. its stretchability, and thus the final carbon fiber properties are highly influenced by the process conditions, i.e. the temperatures and residence times, during the
- the final carbon fiber is obtained as the intermediate carbon fiber is thermally treated at
- the cellulose and lignin were mixed with N- methylmorpholine-N-oxide hydrate and heated at 90 °C at 50 mbar until a NMMO content of at least 87% was attained and the dope was formed.
- the dope was transferred to the spinning pump by a single screw-extruder. The throughput as well as drawing from the nozzle was adjusted so that total fineness of the final single-filament was 7-8 dtex.
- the dope was spun using a nozzle having 70 holes with diameters of 0.1 to 0.25 mm. A 40 mm air gap was realized between the nozzle and the coagulation bath. A constant air flow in the air gap was supplied to discharged dope.
- the multifilament was coagulated in the coagulation bath and passed through a washing bath filled with hot water followed by washing with distilled water using three Nelson Type rollers.
- the multifilament yarn was dried in a 2-stage drying roll to obtain lignin-cellulose containing precursors.
- Three 70 multifilament precursor reels were combined to one 210 multifilament precursor reel.
- Example 2 An endless, continuous multifilament precursor yarn consisting of 210 filaments and comprised of 100 wt % cellulose and was produced analogously to the method described in example 1.
- the precursor from example 1 was transported continuously through two tubular furnaces as shown in Figure 1.
- the stabilization step according to the present invention takes place in the lower furnace shown in figure 1.
- the atmosphere in the stabilization oven is a hot air stream with temperatures between 240 and 270 °C (Tl to T3 in Figure 1) .
- the multifilament precursor yarn is transported through the furnace such that residence times are between 20 and 80 minutes.
- the precursor yarn is converted to a stabilized precursor yarn that is neither meltable nor fusible and free of filament sticking and that is stretchable.
- various heating rates were realized (see table 1) .
- Five different stabilized filament yarns (examples 3 to 7) were produced by varying final stabilization temperature and heating rate (see table 2) .
- Precursor Heating Residence Behavior of precursor Mechanical Performance of the lignin/ rate up time during ; stabilization stabilized fiber
- Table 2 Different stabilized lignin-cellulose multifilament yarns (examples 3 - 7) using precursor from example 1 that were stabilized using different stabilization profiles and the resulting stretchability of the stabilized fiber in the
- the stabilized fibers (examples 3 to 7) are treated in a stretch-pre- carboni zation step.
- Stretch pre-carbonization is carried out at temperatures (T 6 - T 4 ) between 300 and 900 °C in an inert gas such as nitrogen with residence times between 5 and 30 minutes.
- FIG. 2 shows as mentioned the Wide angle X-ray scattering (WAXS) flat film photographs from these five examples.
- WAXS Wide angle X-ray scattering
- Example 8 The intermediate carbon fibers from Example 8 (-17% stretch) was subsequently carbonized at 1600°C to give a carbon fiber (example 13) .
- Example 11 Analogously, the intermediate carbon fiber from Example 11 (100% stretch) was carbonized at 1600°C to give a carbon fiber (example 14) .
- WAXS flat film photographs were taken from examples 13 and 14.
- Figure 3 shows a WAXS flat film photograph of intermediate C-fiber produced with -17% stretch (example 8) and that of the corresponding carbon fiber (example 13) .
- Figure 4 shows a WAXS flat film photograph of intermediate C-fiber produced with 100% stretch (example 11) and that of the
- Table 3 Applied stretch ratios in the stretch pre-carboni zation step and the resulting moduli of the intermediate carbon fibers (examples 8 - 12) .
- An endless, continuous precursor yarn consisting of 210 filaments based on a dope having the composition of 7.7 wt % cellulose and 11.6% wt% lignin was produced according to the method described in patent publication WO2012156441A1.
- the resulting precursor yarn was stabilized at 240 °C to a stabilized precursor yarn.
- the resulting stabilized precursor yarn was then treated in a stretch-pre-carbonization step at an applied stretch of 200% to give a highly oriented intermediate carbon fiber.
- This intermediate carbon fiber was then carbonized to a carbon fiber at 2000°C at 0% stretch for 5 minutes.
- the resulting carbon fiber thus a highly oriented carbon fiber, had an average elastic modulus of 100 GPa and an average tensile strength of 1.1 GPa with maximum values of 105 GPa for modulus and 1.27 GPa for tensile strength.
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Abstract
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CA2987025A CA2987025C (en) | 2015-06-11 | 2016-06-09 | A fiber and a process for the manufacture thereof |
CN201680033965.8A CN107709639B (en) | 2015-06-11 | 2016-06-09 | Fiber and method for producing same |
KR1020177034742A KR102520803B1 (en) | 2015-06-11 | 2016-06-09 | Fibers and processes for their manufacture |
NZ737376A NZ737376A (en) | 2015-06-11 | 2016-06-09 | A fiber and a process for the manufacture thereof |
EP16806992.0A EP3307931A4 (en) | 2015-06-11 | 2016-06-09 | A fiber and a process for the manufacture thereof |
MX2017015194A MX2017015194A (en) | 2015-06-11 | 2016-06-09 | A fiber and a process for the manufacture thereof. |
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RU2018100174A RU2718749C2 (en) | 2015-06-11 | 2016-06-09 | Fibre and method for production thereof |
BR112017026630-0A BR112017026630B1 (en) | 2015-06-11 | 2016-06-09 | A FIBER AND A PROCESS FOR MANUFACTURING IT |
AU2016276410A AU2016276410B2 (en) | 2015-06-11 | 2016-06-09 | A fiber and a process for the manufacture thereof |
US15/580,826 US10626523B2 (en) | 2015-06-11 | 2016-06-09 | Fiber and a process for the manufacture thereof |
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US20240052530A1 (en) * | 2020-08-25 | 2024-02-15 | The Texas A&M University System | Lignin Fractionation and Fabrication for Quality Carbon Fiber |
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RU2705971C1 (en) * | 2019-06-20 | 2019-11-12 | Акционерное общество "Научно-исследовательский институт конструкционных материалов на основе графита "НИИграфит" | Method of producing carbon graphitized fibrous materials |
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AU2016276410B2 (en) | 2020-06-18 |
RU2718749C2 (en) | 2020-04-14 |
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US20180163326A1 (en) | 2018-06-14 |
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RU2018100174A (en) | 2019-07-11 |
EP3307931A1 (en) | 2018-04-18 |
BR112017026630A2 (en) | 2018-08-21 |
AU2016276410A1 (en) | 2017-12-07 |
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CA2987025C (en) | 2023-06-13 |
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