Carboxyl functionalization of carbon fibers via aryl diazonium reaction in molten urea to enhance interfacial shear strength

Graphical abstract: - Highlights: • Carbon fibers are functionalized with benzoic acid groups via aryl diazonium reaction. • Interfacial shear strength of the carbon fibers increases by 66%. • Tensile strength of the carbon fibers is preserved after grafting reaction. • The treatment in molten urea can improve modification efficiency greatly. • Using molten urea as the reaction medium can avoid pollution from organic solvents. - Abstract: Using molten urea as the solvent, carbon fibers were functionalized with carboxylic acid groups via aryl diazonium reaction in 15 min to improve their interfacial bonding with epoxy resin. The surface functionalization was quantified by X-ray photoelectron spectroscopy, which showed that the relative surface coverage of carboxylic acid groups increased from an initial percentage of 3.17–10.41%. Mechanical property test results indicated that the aryl diazonium reaction in this paper could improve the interfacial shear strength by 66%. Meanwhile, the technique did not adopt any pre-oxidation step to produce functional groups prior to grafting and was shown to maintain the tensile strength of the fibers. This methodology provided a rapid, facile and economically viable route to produce covalently functionalized carbon fibers in large quantities with an eco-friendly method.