Journal of Textile Research ›› 2026, Vol. 47 ›› Issue (1): 240-249.doi: 10.13475/j.fzxb.20250304802

• Comprehensive Review • Previous Articles     Next Articles

Research applications and prospect of carbon fiber nonwovens

WANG Shihao1, XU Xiaoyu2, ZHENG Ting3, WANG Jinxing4, YAO Degang5, WANG Jun5, YE Xiangyu6, TIAN Hui7, LI Ting8, ZHU Feichao1()   

  1. 1. National Key Laboratory of Bio-based Fiber Materials, Zhejiang Sci-Tech University, Zhejiang, Hangzhou 310018, China
    2. Jianghua New Materials Technology (Jiangsu) Co., Ltd., Nantong, Jiangsu 226000, China
    3. Zhejiang Lantianhewu Holding Co., Ltd., Hangzhou, Zhejiang 311200, China
    4. Hangzhou Advanced Nonwoven Co., Ltd., Hangzhou, Zhejiang 310018, China
    5. Qingdao Jianqi Electromechanical Technology Co., Ltd., Qingdao, Shandong 266100, China
    6. Zhejiang Institute of Quality Sciences, Hangzhou, Zhejiang 310018, China
    7. Eastex Industrial Science & Technology Co., Ltd., Langfang, Hebei 065001, China
    8. China Textile Academy Co., Ltd., Beijing 100025, China
  • Received:2025-03-24 Revised:2025-11-11 Online:2026-01-15 Published:2026-01-15
  • Contact: ZHU Feichao E-mail:zhufeichao@zstu.edu.cn

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Abstract:

Significance Carbon fiber nonwoven materials are fabricated from carbon fibers or their precursors (e.g., polyacrylonitrile (PAN) and pitch) by various nonwoven forming technologies. These materials integrate the inherent properties of carbon fibers such as wear resistance, ablation resistance, and electrical conductivity with the advantages of nonwoven manufacturing, including high production efficiency and flexible regulation of product structure and functionality. Consequently, they exhibit broad application prospects across multiple fields. For instance, needle-punched carbon fiber nonwovens are widely used in brake discs, rocket nozzles, and nose cones, benefiting from their excellent wear and ablation resistance. Carbon fiber membranes prepared by centrifugal spinning and electrospinning hold great potential in electrode materials and electromagnetic shielding applications. Meltblown carbon fiber nonwovens possess both filtration and adsorption capabilities, while spunlaced carbon fiber nonwovens are suitable for thin insulation materials in high-speed railways.

Progress This paper comprehensively reviews the research progress of carbon fiber nonwoven materials, starting from their preparation by different technologies. Based on the technical and product characteristics of various carbon fiber nonwovens, a detailed analysis is conducted from the perspectives of raw materials, preparation processes, equipment, and application fields. Needle-punched carbon fiber nonwovens are characterized by high production efficiency and adjustable product shapes, thus ideal for high-demand composites requiring superior mechanical resistance (e.g., ablation-resistant and wear-resistant materials). Electrospinning, which enables the preparation of nanoscale carbon fibers, has attracted extensive attention and research from scholars. In the study of wet-laid carbon fiber nonwovens, researchers have continuously proposed innovative solutions to address the key challenge of uniform dispersion of carbon staple fibers. Meanwhile, equipment for meltblown and centrifugal-spun carbon fiber nonwovens is constantly upgraded to achieve stable and consistent production. Regarding applications, this paper focuses on the utilization of carbon fiber nonwovens in high-resistance materials, electromagnetic shielding materials, adsorption/filtration materials, and energy storage systems.

Conclusion and Prospect Advancements in nonwoven and carbon fiber technologies have laid a solid foundation for the development of carbon fiber nonwoven materials, enabling their high performance and multifunctionality and thus ensuring excellent performance across diverse fields. This paper prospects the future development trends of carbon fiber nonwoven materials as follows: 1) ultra-refinement: ultra-fine carbon fibers offer large specific surface area and high entanglement density, which can enhance the versatility of carbon fiber nonwovens and expand their applications in electrode materials, battery separators, adsorption/filtration materials, and electromagnetic shielding materials. 2) Green engineering: currently, research on Lyocell-based carbon fiber nonwovens is limited, with a focus on adsorption capacity. Future efforts should address the low carbon yield and poor performance of Lyocell-based carbon fibers to realize the green production of carbon fiber nonwovens. 3) Energy saving: the carbonization process of pitch-based and PAN-based felts consumes substantial energy and may suffer from uneven carbonization. Therefore, it is necessary to upgrade pre-oxidation and carbonization methods and equipment tailored to carbon fiber nonwovens to achieve energy efficiency. 4) Recycling: recycled carbon fiber staple fibers, obtained by crushing discarded carbon fiber filament products, can be used for the preparation of needle-punched and wet-laid carbon fiber nonwovens, promoting resource reuse.

Key words: carbon fiber, nonwoven, needle punching, spunlacing, wet-laid web forming, electrospinning, centrifugal spinning, meltblowing

CLC Number: 

  • TS174

Tab.1

Comparison of fiber characteristics and typical applications of carbon fiber nonwoven materials by different processes"

工艺 纤维直径/μm 典型应用
针刺法[1] 10~20 刹车盘、火箭喉衬、耐烧蚀材料
水刺法[2] 5~10 高铁飞机防寒保温吸音材料
湿法[3] 5~10 燃料电池气体扩散层、
电磁屏蔽材料
熔喷法[4] 0.5~5 空气吸附过滤材料、
电磁屏蔽材料
静电纺丝法[5] 0.05~0.5 锂电池电极、吸附材料、
柔性屏蔽膜
离心纺丝法[6] 0.3~1 锂电池电极、电磁屏蔽材料、
高效吸附膜

Fig.1

Process flow chart of preparing carbon fiber paper by wet method"

Fig.2

Schematic diagram of equipment for manufacturing bituminous carbon fiber melt blown nonwoven material"

Fig.3

Process flow diagram of preparation of hollow PAN based carbon nanofibers by coaxial electrostatic spinning"

Fig.4

Schematic diagram of centrifugal spinning with ring and plane collection devices"

Tab.2

Properties comparison of different carbon fibers and metal materials"

材料 导热系数/
(W·(m·K)-1)		 耐摩擦
性能		 耐热温度/
℃		 密度/
(g·cm-3)
PAN 基碳纤维 100~300 良好 2 000 1.7~1.9
高性能沥青
基碳纤维		 800~1 200 优异 >2 000 1.9~2.1
通用级沥青
基碳纤维		 300~600 中等 >1 500 1.6~1.9
纤维素基
碳纤维		 200~400 中等 >1 000 1.5~1.7
钢 40~60 中等 1 540
(熔点)		 7.8~7.9
铝合金 200~240 较差 660
(熔点)		 2.7

Fig.5

Schematic diagram of laser-assisted heating meltblow die head"

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