Solvent infusion processing of all-cellulose composite materials

► A solvent infusion process was developed to produce thick all-cellulose composites. ► Applied pressure during cellulose dissolution results in high levels of compaction. ► The described process results in composites with good tensile properties. ► No dimensional shrinkage or warpage is observed. Continuous fibre-reinforced all-cellulose composite (ACC) laminates were produced in the form of a dimensionally thick (>1mm) laminate using an easy-to-use processing pathway termed solvent infusion processing (SIP) from a rayon (Cordenka™) textile using the ionic liquid 1-butyl-3-methylimidazolium acetate. SIP facilitates the infusion of a solvent through a dry cellulose fibre preform with the aim of partially dissolving the outer surface of the cellulose fibres. The dissolved cellulose is then regenerated by solvent exchange to form a matrix phase in situ that acts to bond together the undissolved portion of the fibres. SIP is capable of producing thick, dimensionally stable ACC laminates with high volume fractions of continuous fibres (>70vol.%) due to the combination of two factors: (i) homogeneous and controlled partial dissolution of the fibres and (ii) the application of pressure during regeneration and drying that provides a high level of fibre compaction, thereby overcoming void formation associated with material shrinkage. The effect of inlet and outlet positioning, and applied pressure on the macro- and microstructure of all-cellulose composites is examined. Finally, SIP expands the applications for ACCs by enabling the production of thick ACC laminates to overcome the limitations of conventional thin-film ACCs.