Abstract
Polyacrylonitrile (PAN) is a key industrial polymer for the production of carbon fiber for high-strength, lightweight composite material applications, with an estimated 90% of the carbon fiber market relying on PAN-based polymers. Traditionally, PAN synthesis is achieved by conventional radical polymerization, resulting in broad molecular weight distributions and the use of toxic organic solvents or surfactants during the synthesis. Additionally, attempts to improve polymer and processing properties by controlled radical polymerization methods suffer from low monomer conversions and struggle to achieve molecular weights suitable for producing high-performance carbon fiber. In this study, we present an aqueous photoiniferter (aqPI) polymerization of acrylonitrile, achieving high monomer conversion and high PAN molecular weights with significantly faster kinetics and dispersity control when compared to traditional methods. This approach allows for the unprecedented control of polymer properties that are integral for downstream processing for enhanced carbon fiber production.