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Polyacrylonitrile copolymers with different molecular weights (Mws) are synthesised by aqueous free-radical redox polymerisation technique. Polyacrylonitrile (PAN) and lignin-blended solutions are prepared in dimethyl sulphoxide solvent by varying the polyacrylonitrile/lignin content. The effect of lignin addition to PAN copolymer having different weight-average Mws on the rheological properties is explored. Rheological measurements indicate that the solution viscosity reduces with the increase in the lignin content. The Cole–Cole plot or Han plot and Casson plot are used to characterise the solution homogeneity. The slope value of the plot suggests that the molecular-level homogeneity of the solution is not affected much by the addition of lignin. Thermal-induced gelation of concentrated solution has been rheologically investigated to avoid overheating of solution during the dissolution, storage and transportation for further wet spinning process.

Polyacrylonitrile copolymer (PAN) fiber and PAN/lignin (PL) fiber were wet spun from the PAN copolymer solution and PAN/Lignin blend solution using dimethyl sulphoxide (DMSO) solvent. A blend of 90% by weight (wt %) PAN terpolymer and 10wt% lignin dissolved in DMSO was used in wet spinning of PL fiber. Viscoelastic properties of PAN solution and PAN/lignin solution in DMSO were determined by rheometer. The properties of precursor fiber with and without lignin were evaluated by differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR) and mechanical testing. The diffusion of lignin out of coagulated filament was observed during wet spinning of PL solution and was quantitatively estimated by UV–Vis studies. DSC results showed that blending lignin with PAN copolymers can improve the thermal oxidation performance of the precursor fiber and accelerate the thermal stabilization process. A schematic illustration has been deduced for the decrease in tensile strength of PL fiber compared to that of PAN fiber.