Weizhe Zhao,
Yonggen Lu*,
Junqi Jiang,
Leiyang Hu and
Liangxiao Zhou
State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Materials Science and Engineering, Donghua University, Shanghai 201620, China. E-mail: yglu@dhu.edu.cn; Tel: +86 21 67792936
First published on 24th February 2015
In this paper, not only the effect of γ-ray irradiation on the chemical structures and thermal properties of PAN fibers, but also the corresponding reaction mechanisms are investigated. We report a new solubility measurement adopting sulfuric acid solution as a solvent to deeply discern cyclization and crosslinking reactions of PAN fibers after γ-ray irradiation. After the irradiation, the intramolecular cyclization of PAN fibers was dominant at relatively low doses (<200 kGy), while intermolecular crosslinking in amorphous regions dominates at higher doses. Moreover, the irradiation had an obvious effect on crystal dimensions and crystallinity but only a very slight influence on the orientation of the precursor fibers. The crosslinking and cyclization mechanisms were also analyzed using Fourier transform infrared spectroscopy and differential scanning calorimetry. The thermal behavior of PAN precursor fibers demonstrated that the manipulation range of applied stress during the following thermal stabilization could be amplified by the intermolecular crosslinking due to the pre-irradiation treatment, which would be beneficial for depressing the molecular disorientation during thermal stabilization.
Very recently, ionizing radiation, such as γ-ray,8–11 electron beam,12–14 UV15,16 and X-ray,17 has been widely used in modification of polymeric materials by initiating reactions or inducing crosslinking.18,19 Some investigations on irradiation of PAN fibers indicated that the insolubility of molecules was increased, the initial reaction temperature was decreased, and the free radicals were preserved.20,21 Zhao W. W et al.22 concluded that the free radicals induced by irradiation could initiate thermal chemical reaction. Tarakanov8 reported that irradiated PAN samples could be oxidized much more rapidly than the unirradiated ones, implying that irradiation indeed accelerated the formation of ladder structures. However, whether and how the crosslinking takes place during irradiation are far more than clear.
Some researchers deem that the crosslinked structure in irradiated PAN fibers can be determined by the insolubility in dimethylsulfoxide (DMSO) or dimethyl formamide (DMF).9,14,15,23 However, to our knowledge, the crosslinking can't be distinguished from cyclization using the insolubility in these solvents. Therefore, more detailed work is needed to verify the effect of the γ-ray irradiation on the structure of PAN fibers and clarify the reaction mechanism.
In this work, we report a new solubility measurement adopting sulfuric acid solution as a solvent to deeply discern cyclization and crosslinking reactions of PAN fibers after γ-ray irradiation. Combining with the insolubility in DMSO, we definitely distinguished crosslinking from cyclization and quantified the proportion of cyclization and crosslinking in irradiated fibers. Meanwhile, the thermal behaviors of unirradiated and irradiated PAN fibers are analyzed.
The insoluble fraction of the fibers in DMSO was measured by immersing the fibers into DSMO at room temperature for 24 h, then separating, weighing and calculating similarly. Densities of fibers were measured by a sink–float method with a PZ-B-5 liquid specific gravity balance according to the Chinese Standard GB3362-82.
Differential scanning calorimetry (DSC) measurements were performed on a TA-Q20 (TA instruments) differential scanning calorimeter at 10 °C min−1 under nitrogen atmosphere. The degree of cyclization (Dc) of the fibers was calculated by the exothermal enthalpy as follows.24,25
(1) |
Fourier transform infrared spectroscopy (FTIR) of KBr disks were measured on a Thermo Nicolet 8700 FTIR spectrophotometer at room temperature; 32 scans were collected at a resolution of 1 cm−1.
Wide-angle X-ray diffraction (WXRD) was used to investigate the crystallite structures on a D/Max-2550 PC XRD apparatus (Cu Kα, 0.154056 nm, 40 kV, 250 mA) by arranging a fiber bundle perpendicular to the incident ray. The crystallinity (Xc) was calculated from the areas of the crystalline diffraction peaks using Bell and Dumbleton method by Origin 8.0 software shown in the literature.26
The crystallite stack height Lc (100) and the crystallite width La (100) were determined by (100) reflection, and the values were calculated using the Scherrer equation, respectively. The shape factor, k, was taken as 0.9 for the crystallite heights and 1.84 for the crystallite widths. The full width at half maximum (FWHM) of the diffraction peak from the azimuthal scan was used to estimate the degree of orientation (R)27,28
(2) |
(3) |
The stress and strain behaviors of the fibers were measured with a fiber bundle containing 100 filaments on a TA-Q800 (TA instruments) dynamic mechanical analysis (DMA) at 5 °C min−1 under a nitrogen gas flow. For stress measurements, a controlled strain of 0.05% was applied to maintain a constant length. And for strain tests, a constant force of 0.15 N (0.15 cN at each signal filament, equal to a constant stress of 12.75 MPa calculated based on the diameter of precursor fibers) was carried out on the fiber bundle.
Fig. 1 shows the solubilities of fully cyclized structure fibers without crosslinking (FC-F) in DMSO and sulfur acid respectively, and the solubilities of PAN fibers at various doses of 0, 50, 100, 200, 300, 400 kGy in sulfur acid. As shown in Fig. 1, the FC-F isn't dissolved in DMSO even the color has a little change, however, it is fully dissolved in sulfur acid which results in the formation of reddish-brown solution. For PAN fibers, the solubility in sulfur acid decreases and the color is thicker and thicker with the increase of irradiation doses. Therefore, the results indicate the FC-F can't be dissolved in DMSO, whereas, it can be fully dissolved in sulfur acid. In other words, the DMSO solvent is unable to dissolve the cyclized structures in PAN fibers. Therefore it is for sure that the insolubility in DMSO is inadequate to verify crosslinking taking place during irradiation. However, the irradiated fibers from IR-1 and IR-2 can be but IR-3, IR-4 and IR-5 can't be completely dissolved in the sulfur acid even the solutions' color is much lighter than that from FC-F (b). Thus, it is estimated that the DMSO insoluble is related to the parts of both cyclized and crosslinked, while the sulfur acid insoluble is only related to the crosslinked part. Fig. 2(a) shows the insoluble fraction quantities of the irradiated fibers with different doses in DMSO and sulfur acid, respectively. It is noted that the insoluble fraction in DMSO increases from 13.04% at 50 kGy to 68.3% at 400 kGy monotonously. In sulfur acid, the unirradiated and the irradiated fibers at the doses of 50 and 100 kGy are dissolved completely, however, the insoluble fraction yields to approximately 31.8% at 200 kGy, and then increases gradually to 59.7% with the irradiation dose increasing to 400 kGy. What's more, the density of the fibers increases from 1.174 g cm−3 of unirradiated fibers to 1.197 g cm−3 of the 400 kGy irradiated fibers as shown in Fig. 3, which should be resulted from the reactions induced by irradiation forming the denser structure.9 Therefore, the phenomenon that the solutions looking more uniform from IR-3 to IR-5 can be ascribed to the fiber density increasing which made the insoluble sink and look dispersed well.
Fig. 1 Solubility of FC-F immersed in (a) DMSO solvent and in (b) sulfur acid, and PAN fibers of UN, IR-1, IR-2, IR-3, IR-4, IR-5 in sulfur acid. |
Fig. 2 (a) DMSO and sulfur acid insoluble of the PAN fibers induced by γ-ray irradiation at various doses, respectively; (b) subtraction of sulfur acid insoluble from DMSO insoluble. |
By subtracting the insoluble fraction curves in sulfur acid from those in DMSO, the fraction quantity of cyclization without crosslinking (we name as independent cyclization) is obtained. As shown in Fig. 2(b), the fraction quantity of independent cyclization increases with irradiation doses increasing and reaches a maximum at 100 kGy, then decreases with further irradiation. Therefore, it is clearly found that cyclization of nitrile groups is dominant at 100 kGy and below, and further irradiation generates inter-crosslinking.
Fig. 4 FTIR curves of PAN fibers at various doses. (a) 0 kGy; (b) 50 kGy; (c) 100 kGy; (d) 200 kGy; (e) 300 kGy; (f) 400 kGy. |
It is fairly agreed that how cyclization, dehydrogenation and oxidation or even crosslinking reactions take place by thermal treatment. However, how crosslinking occurs during irradiation is still not so clear. Herewith three proposed types of crosslinking mechanism are presented in Fig. 5. Above all, backbone radicals are generated by break of C–H bond under γ-ray irradiation.21 The first mechanism, by which so-called crosslinking of “H” type may generate by recombination of two backbone radicals or by one backbone radical adding to a nitrile group on an adjacent chain and initiating cyclization, is mentioned in some literatures.9,34 By the second mechanism, the radical transfers to the end of the chain forming terminal radical, and recombines or adds in a similar way. When the terminal radical recombines with a backbone radical or adds to a nitrile group on an adjacent chain, the crosslinking of “Y” type is formed. What needs to emphasize is the third mechanism proposed by us, by which the crosslinking takes place due to presence of oxygen. Addition of O2 to the backbone radicals leads to the generation of backbone-peroxy radicals. Then one O atom is lost by attacking of H2 to produce backbone-oxygen radicals.35 After that, the backbone-oxygen radicals may recombine with C atoms on adjacent molecule chains to crosslink or add to a nitrile group on adjacent chains to initiate cyclization. Subsequently, an intermolecular oxygen crosslinking model at high irradiation doses is formed as shown in Fig. 6.
The insolubility and FTIR analysis verify the reactions of cyclization and crosslinking takes place during γ-ray irradiation, and the cyclization ratio is also determined by DSC analysis. Fig. 7 shows DSC curves of the unirradiated and irradiated PAN fibers in nitrogen atmosphere. It is noted that two exothermic peaks are found at approximately 259 and 272 °C for the unirradiated fibers, respectively, corresponding to the two step initiation of cyclization by the comonomers of acrylamide (AM) which is also similar to the reported data in the literature.36 As anticipated, the initial reaction temperature shifts to lower temperature and the total area of exothermal peak decreases with increase of irradiation doses. However, it is curious that the temperature of the second exothermal peak increases with increasing irradiation doses, which will be interpreted later.
The Dc for each irradiated fibers is calculated by the heat release according to the formula in the experimental section and drawn in Fig. 8. It is noted that the Dc increases with increase of irradiation doses monotonically which obeys first order reaction as we discussed elsewhere.37 In order to quantify the relationship between Dc and irradiation doses, we assume that De is the maximal possible degree of cyclization in the unit volume, and the degree of newly produced cyclization (dy) in time dt of irradiation is proportional to the intensity of irradiation, I, so the equation is obtained:
(4) |
By integrating the eqn (4), we get the relationship:
y = De[1 − exp(−KIt)] = De[1 − exp(−Kx)] | (5) |
Based on the experiment data of Dc after irradiation, we regressed the data according to eqn (5) (the line in Fig. 8) by Origin 8.0 software and the results matched extremely well with the experiment data (R2 = 0.9785). The parameters De and K were regressed as follows:
y = 0.1675[1 − exp(−0.004x)] | (6) |
According to our speculation, the Dc of the irradiated PAN fibers increases quickly with increasing irradiation doses at initial stage and will gradually reach a saturation of 16.75% at unlimited irradiation dose. We think this is reasonable because the limitation of molecules movement leads to inhibiting completely cyclizing during γ-ray irradiation.
Based on the understanding of cyclization mechanism and irradiation inducing structure, we try to give some comprehension for the DSC results, as shown in Fig. 9. First of all, the cyclization mechanism of the molecules without irradiation during heat treatment is shown in Fig. 9(1). The first N–H bond on amide group in AM breaks away at a lower active energy and makes a nucleophilic attack on the carbon atom of adjacent nitrile groups and then induces cyclization propagation and generates the first exothermal peak 26. We name this cyclization pathway as C1. Then another N–H bond on amide group is attracted by the carbonyl group to form hydroxy and the O–H bond will break at a higher active energy and then induce cyclization propagation and generate the second exothermal peak (C2). As analyzed above, not only the free radicals but also intermolecular crosslinking took place during irradiation. When a free radical exists in the neighbor position of the amide group before the first N–H bond breaks away, it can reduce the active energy of N–H bond and make the first exothermal peak appear in advance. However, when a crosslinkage exists in the neighbor position of the amide group just before the second N–H breaks away, it can enhance the active energy and make the second exothermal peak appear later. However, the intensity of the second exothermal peak decreases gradually with increasing irradiation doses, which could be ascribed to the partial cyclization induced by irradiation reducing heat release.9,38 Therefore, the intramolecular cyclization of PAN molecule chain is obtained as shown in Fig. 10.
Fig. 10 A model of intramolecular cyclization of a fragment of a PAN molecule chain –[CH2–CHCN]– at low irradiation doses(<200 kGy). |
Fig. 11 XRD patterns of PAN fibers at various doses (a) equatorial scan; (b) Azimuthal scan on (100) crystal face. |
Dose (kGy) | 2 theta (°) | Lc (nm) | La(nm) | Xc (%) | R (%) |
---|---|---|---|---|---|
0 | 16.54 | 11.3 | 23.2 | 56.7% | 89.5% |
50 | 16.62 | 12.1 | 24.6 | 57.9% | 89.3% |
100 | 16.54 | 12.6 | 25.7 | 56.4% | 89.6% |
200 | 16.66 | 12.7 | 25.9 | 56.4% | 89.4% |
300 | 16.54 | 13.0 | 26.5 | 55.7% | 89.1% |
400 | 16.64 | 13.2 | 27.0 | 52.0% | 89.6% |
Fig. 12 shows that the XRD diffraction patterns of the insoluble in sulfur acid derived from the irradiated fibers at the doses of 200, 300, 400 kGy. It is noted that the sharp peak for crystallite disappears and a new broad diffraction peak appears approximately at 2θ = 19.4°. Clearly, the crystallite structure changes due to the dissolution by sulfur acid and thus the insoluble is primarily the residue of the amorphous region and a few cyclized and crosslinked molecules. Based on the above results, it is obvious that cyclization and crosslinking induced by γ-ray irradiation mainly occur in amorphous regions.
According to our knowledge, the strain and stress behaviors are determined by two actions above 175 °C, one is the sliding between molecule chains due to nitrile groups force decays and the other is the shrinkage due to cyclization of nitrile groups.41 The existence of crystallites as well as at 175–230 °C and the crosslinked structure induced by irradiation prevent the sliding between the molecule chains at higher temperature. Therefore, up to 300 kGy, the higher dose is, the more the fibers shrink or the higher the stress arrives because irradiation of higher doses generates more crosslinking inhibiting the sliding greatly. When the irradiation dose increases to 400 kGy, the damage of crystallite and generation of more cyclized structure during irradiation make the molecules chains slide easily and lead to less shrinkage than that of 300 kGy. After 335 °C, the crosslinking is overcome, resulting in the fibers extension or stress decay till break.
The final strains of the PAN fibers during stabilization in air at a series of constant stress are further investigated, as shown in Fig. 14. Based on our previous results, applying appropriate stress on fibers is necessary to restrict the disorientation during thermal treatment.5,7 From Fig. 14, as the applied stresses increases, the shrinkage for all the final stabilized fibers is decreased gradually or the extension is increased. On the contrary, at the same initial stress, the shrinkage is increased or the extension is decreased with increasing irradiation doses. It is notable that other fibers break at 27 MPa, but only the 400 kGy irradiated fibers don't and extend by 18.81%. This suggests that the PAN molecule chains are cured through crosslinking induced by γ-ray irradiation, which is benefit for amplifying manipulation range of applied stress during stabilization process. Thus we expect to maintain the orientation of PAN molecule chains and obtain high performance carbon fibers through irradiation technology.
Additionally, the exothermic behavior of cyclization reaction was significantly alleviated and the sliding of molecules was prevented by the crosslinking introduced by γ-ray irradiation during stabilization, which might effectively inhibit the thermal disorientation of PAN fibers during the following stabilization and alleviate the skin–core structure due to the lack of oxidation in the fiber core.
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