Carbon nanofibers are produced from dielectric polymer precursors such as polyacrylonitrile (PAN). Carbonized nanofiber nonwovens show high surface area and good electrical conductivity, rendering these fiber materials interesting for application as electrodes in batteries, fuel cells, and supercapacitors. However, thermal processing is slow and costly, which is why new processing techniques have been explored for carbon fiber tows. Alternatives for the conversion of PAN-precursors into carbon fiber nonwovens are scarce. Here, we utilize an atmospheric pressure plasma jet to conduct carbonization of stabilized PAN nanofiber nonwovens. We explore the influence of various processing parameters on the conductivity and degree of carbonization of the converted nanofiber material. The precursor fibers are converted by plasma-jet treatment to carbon fiber nonwovens within seconds, by which they develop a rough surface making subsequent surface activation processes obsolete. The resulting carbon nanofiber nonwovens are applied as supercapacitor electrodes and examined by cyclic voltammetry and impedance spectroscopy. Nonwovens that are carbonized within 60 s show capacitances of up to 5 F g−1.

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Carbon nanofiber nonwovens represent a powerful class of materials with prospective application in filtration technology or as electrodes with high surface area in batteries, fuel cells, and supercapacitors. While new precursor-to-carbon conversion processes have been explored to overcome productivity restrictions for carbon fiber tows, alternatives for the two-step thermal conversion of polyacrylonitrile precursors into carbon fiber nonwovens are absent. In this work, we develop a continuous roll-to-roll stabilization process using an atmospheric pressure microwave plasma jet. We explore the influence of various plasma-jet parameters on the morphology of the nonwoven and compare the stabilized nonwoven to thermally stabilized samples using scanning electron microscopy, differential scanning calorimetry, and infrared spectroscopy. We show that stabilization with a non-equilibrium plasma-jet can be twice as productive as the conventional thermal stabilization in a convection furnace, while producing electrodes of comparable electrochemical performance.