The wet-spinning of chitin fibers
Chitin fibers were produced by wet-spinning as illustrated in Fig. 1. Firstly, the raw chitin powders were purified to obtain pure chitin and then subjected to alkaline deacetylation for a certain time to acquire partially deacetylated chitin with different DD (Fig. 1a). The structural transformations of chitin during deacetylation were confirmed by X-ray diffraction (XRD) patterns, which showcased diffraction peaks corresponding to specific chitin crystal reflections (Fig. 1b). It can be found that the diffraction peaks at 2θ = 9.4°, 12.9°, 19.3°, 20.9°, 23.4°, 26.4°, corresponding to the reflection of chitin crystals (020), (021), (110), (120), (130) and (013), respectively. With deacetylation, the characteristic diffraction peaks of chitin crystals are gradually diminished. Only two distinct characteristic diffraction peaks at 9.4° and 20.9° appear in CH-58, which is attributed to 020 and 200/220 diffraction peaks originating from chitosan hydrated crystals, respectively(Ogawa et al. 2004; Chen et al. 2021; Zhang et al. 2021). The changes in XRD patterns indicate that the acetyl groups are successfully removed and aggregate structure changes on deacetylation. Further analysis through solid CP/MAS 13C NMR spectra quantified the DD in the partially deacetylated chitin (Fig. S1 and Table S1). Subsequently, the obtained chitin powder was dissolved in 20 wt% KOH/4 wt% urea aqueous solution under continuous stirring at -32℃. As shown in Fig. 1c, after low-temperature dissolution and centrifugal defoaming, homogeneous solutions were obtained. The coloration of these solutions, which shifted to a deeper yellow upon partial deacetylation. The chitin wet-spinning dope was extruded through a needle and passed through the coagulation bath to acquire gel fibers. After water-washing and drying, the final regenerated fibers with a shiny and uniform appearance were obtained (Fig. 1d, e, f).
3.2 The properties of deacetylated chitin spinning dopes
The properties of the spinning dope are critical for wet-spinning, with its viscosity and stability directly affecting the spinnability, and the solution storability. The alkali/chitin complex forms a hydrogen-bonded structure, encapsulated by urea hydrates, facilitating chitin's effective dissolution in alkali/urea aqueous solutions. (Huang et al. 2020). In such a complex dissolved system, hydrophobic interactions and a large number of entanglements between molecular chains are involved in addition to abundant hydrogen bonding. As shown in Fig. 2a, b, all chitin solutions show a clear shear-thinning behavior, which is advantageous for wet-spinning. At the same DD, the viscosity of the solutions gradually increases with the increase of the content of chitin. A similar tendency is also reflected in the dynamic modulus of the solutions (Fig. 2c), where the storage and loss modulus of the chitin solutions gradually improve with the increase of the concentration, which is attributed to the increase of internal interactions as well as the interchain entanglement brought about by more molecular chains. Interestingly, chitin solutions with higher DD result in lower viscosity and modulus for the same chitin content (Fig. 2c, d). When the concentration of CH-5 further increases to 11%, the storage modulus is higher than the loss modulus at low shear frequency, indicating that the solution has no fluidity and spinnability. With the process of deacetylation, the loss modulus become higher than the storage modulus, the fluidity gradually appears, and the spinnability increases. This may be due to the stronger hydrophobic interactions and molecular chain rigidity resulting from the hydrophobicity and greater steric hindrance of the acetyl group compared with amino group. Generally speaking, the higher the concentration of the solution has a higher solution strength, can withstand stronger drafting and spinning speed, which is more favorable for spinning. On the other hand, lower viscosity is more conducive to the ordered arrangement of molecular chain to construct orientation structure of fibers in the spinning process. Therefore, it is necessary for high-quality spinning to increase the concentration of spinning dope and make it have lower viscosity at high concentrations. What's more, in alkali/urea dissolution system, low temperature is favorable for the stability of the solution, and the increase of temperature will lead to the change of internal interactions, especially the increase of hydrophobic interactions, especially the increase of hydrophobic interaction, resulting in the gelation of the solution. It can be found in Fig. 2e, f that, the gelation temperature of the solutions occurs at higher temperatures with the decrease of the content of chitin and the increase of DD. In other words, the lower content and deacetylation of chitin can weaken the internal interaction of the solution to improve its stability and storability. In conclusion, deacetylation is necessary for the preparation of high-quality spinning dope with high chitin content and excellent storability.
Structural evolution of the regenerated fibers
SEM elucidates the structural evolution of regenerated chitin fibers across different degrees of deacetylation (DD), revealing a transition from interconnected nanofibers to larger pore structures during the regeneration process (Fig. 3a). This self-assembly into a microporous architecture is mediated by a balance of hydrogen bonding and hydrophobic interactions. Notably, the removal of acetyl groups diminishes hydrophobic interactions, allowing for a more extended assembly period for molecular chains in higher DD fibers, leading to the formation of thicker pore walls and enlarged pore structures. Transitioning from nano- to micron-scale pores, the internal structure becomes less dense with increasing DD, impacting the mechanical integrity of the fibers. The SEM images also show that dry fibers exhibit a longitudinally organized micro-structure, contributing to enhanced mechanical strength. With increasing DD, fiber surfaces become smoother, and the micro-structure more compact, indicative of a denser alignment of molecular chains. In Fig. 3c, 2D WAXD is employed to quantitatively assess the orientation of several regenerated fibers. Shearing during spinning induces a high degree of orientation, with the orientation parameter increasing from 0.66 to 0.76 alongside DD (Fig. S2). This increase is attributed to reduced viscosity and steric hindrance from deacetylation, promoting tighter chitin chain contractility and alignment during spinning. These structural and orientational modifications underscore the nuanced relationship between deacetylation, fiber microstructure, and mechanical performance, establishing a foundation for understanding the mechanical properties of regenerated chitin fibers.
Mechanical properties and internal structures of fibers
FT-IR and solid CP/MAS 13C NMR are used to reveal the differences in the internal molecular structure of regenerated chitin fibers with different DD. Firstly, there is no significant change in the DD of chitin during the process of dissolution and regeneration into fibers (Fig. S3). Figure 3a shows the FT-IR spectra, the characteristic absorption peaks at 3455 cm− 1 are attributed to the stretching vibration of O-H, peaks at 3255 cm− 1 and 3109 cm− 1 originate from the stretching vibration of N-H (amide I band), peaks at 1654 cm− 1 and 1642 cm− 1 are attributed to the stretching vibration of C = O (amide II band), and the characteristic peak at 1561 cm− 1 are caused by the bending vibration of N-H (amide II band). On deacetylation, peaks at 1654 cm− 1 are gradually weakened and merge with peaks at 1642 cm− 1, while the absorption peaks of methyl group at 2890 cm− 1 significantly weaken, indicating the gradual reduction of acetylamino group with the production of amino. The peaks of O-H stretching vibration are slightly redshifted from 3455 cm− 1 ( CH-5) to 3453 cm− 1 (CH-58), demonstrating that the deacetylation creates new hydrogen bond (C6-OH⋯NH2) between the chitin chain. It can be found in Fig. 4b that the peaks of C(C-O) at 173.6 ppm and C(CH3) at 22.3 ppm gradually diminish with deacetylation, which corroborates with the FT-IR spectra, proving the reduction of acetyl groups. Moreover, the C2 resonances gradually weaken and shift upfield near C6 resonances, indicating that the conversion from acetylamino to amino group increases the electron cloud density of -NH2 compared with -NH, resulting in the change of C2 resonances. XRD is used to further confirm the difference in the internal aggregation structure of regenerated chitin fibers with different DD. Consistent with the patterns observed in the raw chitin powder, the diffraction peaks of the regenerated fiber do not exhibit significant changes, indicating that the regenerated fiber still retains a crystal structure similar to that of the raw material (Fig. 4c). What’s more, CH-58, unlike the lightly deacetylated chitin fibers, has formed hydrated crystals of chitosan (200/220). The mechanical properties of the fibers are strongly related to the concentration of the spinning dopes and the DD, so, the mechanical properties of regenerated deacetylated chitin fibers spun at different concentrations are evaluated (Fig. 3e, f). The strength and elongation of regenerated fibers are dynamically adjusted within broad ranges of 70–120 MPa and 5%-30%, respectively. As previously discussed, a higher concentration is conducive to increasing the strength of the solution to obtain higher-strength fibers. However, if the concentration becomes excessively high, it may slightly reduce the elongation of the fibers. With an increase in DD, the strength of deacetylated chitin fibers increases primarily due to a tighter and higher orientation structure. When the deacetylated chitin falls within the range of chitin (DD <50%), the removal of rigid acetyl groups and the reduction in crystallinity enhance the mobility of molecular chains (Fig. 4d), thereby increasing the elongation. However, when the DD is further increased (CH-58), the regenerated fiber undergoes a transformation from chitin to chitosan fiber. This transformation significantly alters the crystal type and the degree of orientation, resulting in a slight decrease in elongation.
Thermal and wet performance of fibers
The environmental tolerance of natural polysaccharide fibers, crucial for their application, was assessed through water contact angle measurements and moisture regain properties. (Fig. 5a,b) The introduction of more amino groups through deacetylation significantly enhances hydrophilicity, as evidenced by decreased water contact angles in regenerated deacetylated chitin fibers. the moisture regain properties of the fiber is evaluated at relative humidity (RH) of 81%, which increased from 10.9% of CH-5 to 18.9% of CH-58. Furthermore, due to the plasticizing effect of water molecules, the mechanical strength of the fiber decreases obviously, and the elongation increases greatly. After washing in hot water at 50℃ for 1 h, although the elongation can reach up to 80%, the strength is dropped to within 20 MPa. In addition, in Fig. 5f, deacetylation will reduce the thermal stability of the fiber, so that the thermal degradation of the fiber occurs at a lower temperature, which is mainly caused by the amide group endowing the chitin chain with greater rigidity. It can be seen that although partial deacetylation enhances the mechanical properties of the regenerated fibers, it makes its stability worse.
Antibacterial behaviors
The antibacterial efficacy of chitin/chitosan fibers, especially in forms like surgical sutures, underscores the biomedical significance of this natural polymer(Anitha et al. 2014; Li et al. 2016, 2022b; Shahid-ul-Islam and Butola 2019). The antibacterial activities of chitin fibers with different DD against both the Gram-negative E. coli and Gram-positive S. aureus were tested to further understand the structure-bioactivity of chitin fibers regenerated from KOH/urea solution. As shown in Fig. 5a, all deacetylation samples showed efficient antimicrobial properties against both E. coli and S. aureus compared to the control group. What’s more, the number of colonies on the agar decreased significantly with increasing deacetylation of fibers, especially, the regenerated fibers of raw chitin without deacetylation showed limited antibacterial activity, which indicates the amino exposure originating in deacetylation promotes the antibacterial activity of regenerated chitin. Notably, the inhibition of E. coli is stronger than that of S. aureus in the case of more minor partial deacetylation. There may be an antibacterial mechanism of chitin/chitosan against E. coli and S. aureus: Chitin/chitosan will be adsorbed on the surface of the bacterial cells and interact with it, preventing the entry of nutrients and further disrupting these physiological activities. What’s more, Gram-negative bacteria possess abundant negative charges on the cell surface, which can strongly interact with the amino groups on chitin/chitosan, whereas the interaction of Gram-positive bacteria is comparatively weaker(Li et al. 2016, 2022b). Therefore, a stronger antibacterial effect against Gram-negative bacteria was observed with mild deacetylation, such as CH-5 and CH-14. However, when an ample amount of the antimicrobial factor-amino is exposed with further deacetylation, the disparity in antibacterial efficacy against Gram-negative and Gram-positive bacteria becomes less pronounced, leading to outstanding antibacterial properties against both E. coli and S. aureus.