The Production of Ultra-Thin Polyethylene-Based Carbon Fibers out of an “Islands-in-the-Sea” (INS) Precursor

Carbon fibers (CF) and their composites (CC) are one of the world’s most promising and avant-garde high-performance materials, as they combine excellent mechanical characteristics with high weight reduction potential. Polyethylene (PE) is the perfect alternative precursor for CF as it combines widespread availability, low cost, high carbon content, and, most importantly, precursor fibers that can be produced via melt-spinning. PE-based CF production involves a challenging and time-consuming diffusion-limited chemical stabilization step. The work presented in this article tackles the challenge of reducing the chemical stabilization process time by converting a bicomponent island-in-the-sea fiber, consisting of PA6 as sea matrix and HDPE as island material, into an ultra-thin PE-precursor fiber. The produced precursor fiber is then successfully converted into an ultra-thin PE-based CF through sulfonation and subsequent carbonization in a continuous set-up. The resulting CF has a smooth surface with no observable surface defects and a filament diameter of around 3 µm. The successful conversion to ultra-thin CF is shown in both batch and continuous processes. Additionally, a reduction in sulfonation reaction time from 4 h to 3 h is achieved.