PAN-precursor to carbon fibre: An investigation of manufacture and material properties for varying comonomer composition

This study presents the conversion of polyacrylonitrile (PAN) co-polymers containing methyl acrylate (MA) and varying concentrations of itaconic acid (IA) comonomers, from precursor fibre into carbon fibre using pilot scale continuous processes. The impact of itaconic acid on fibre processability, thermal behaviour, energy consumption, and final mechanical properties during thermal oxidative stabilization (TOS) and carbonization are investigated. Itaconic acid concentration varies from 0.3 to 3 wt% and with increasing concentration of itaconic acid, the precursor fibre exhibited lower exothermicity and enhanced reactivity, resulting in 7% less energy consumption during stabilization. Higher itaconic acid content led to improved carbon fibre properties. A 20% increase in tensile strength was recorded for carbon fibres containing the highest amount of itaconic acid along with a higher amount of graphitic structure and carbon yield. Overall, this study explores the impact of precursor design on fibre properties as a route to the manufacture of carbon fibre with reduced embodied energy. The results of this study illustrate pathways to improve the efficiency and effectiveness of carbon fibre production, and to ultimately create high-performance, lightweight, and more sustainable carbon fibre-reinforced composites.