Poor breathability, inadequate flexibility, bulky wearability, and insufficient gas-adsorption capacity always limit the developments and applications of conventional chemical protective clothing (CPC). To create a lightweight, breathable, and flexible fabric with a high gas-absorption capacity, activated carbon (AC)-loaded poly(m-phenylene isophthalamide) (PMIA) porous composite fibres were fabricated from a mixed wet-spinning process integrated with a solvent-free phase separation process. By manipulating the pore parameters of as-spun composite fibres, the exposure-immobilization of AC particles on the fibre surface can offer a higher gas-absorption capacity and better AC-loading stability. To improve the mechanical properties of AC-loaded porous as-spun fibres and further optimize the pore-locking structures, the impact of the hot-drawing process on the evolution of pore parameters and the corresponding properties (including the gas absorption capacity, the mechanical performance, and the stability of AC particles during loading) was clarified. After the hot-drawing process, the inhomogeneous pore morphologies composed of mesopores/micropores from as-spun fibres changed into homogeneous and decreased mesopores. With the decrease in structural defects in homogeneous morphologies, the tensile strength of AC-loaded PMIA porous-drawn fibres increased to 1.5 cN/dtex. Meanwhile, the greater total pore volume and specific surface area after hot drawing also maintained the gas-absorption capacity of drawn composite fibres at 98.53 mg/g. Furthermore, the AC-loaded PMIA porous composite fibres also showed comparable performance to the commercial FFF02 absorption layer in terms of static absorption behaviour for different gas molecules and absorption–desorption multi-cycling evaluations. In addition, due to the size reduction in mesopores after the hot-drawing process, the loading stability of AC particles in the stretched composite fibres was more substantial.
