Design & characterisation of laminated activated carbon fabric for critical military applications

Abstract

This study aims to prepare activated carbon fabric (ACF) and laminated activated carbon fabric (LACF) from a commercially available rayon-based carbon fabric using CO₂ activation, and to evaluate their functional and physical performance for potential military applications. In the present work, the carbon fabric is activated in a CO₂ atmosphere to produce ACF, which is subsequently characterised for Brunauer–Emmett–Teller (BET) surface area, internal porosity, pore size distribution, average pore diameter and adsorption isotherm behaviour. LACF is then prepared by laminating the ACF with suitable textile substrates on both sides to enhance structural stability and performance. The functional properties of LACF are evaluated through measurements of dichloropropane breakthrough time (DCP-BTT), sulphur mustard breakthrough time (HD-BTT), air permeability and water vapour transmission rate (WVTR). Physical properties in terms of mass, thickness, bending length, flexural rigidity, peel strength, and tensile/bursting strength are also assessed. Durability is examined by comparing these properties before and after six wash cycles. The findings indicate that the prepared LACF exhibits promising adsorption efficiency, robust physical performance and satisfactory durability. Such materials demonstrate strong potential for use in critical military protective systems, which include chemical protective suits, facelet masks and breathable gloves, offering effective protection for personnel operating in chemical warfare environments.