Development of carbon fibre from asphaltene

Abstract

The present disclosure relates to a dope solution for use in wet-spinning precursor fibres for carbon fibre production, the solution comprising a carbon source including asphaltene and polyacrylonitrile in a miscible solvent system. The present disclosure relates to methods for preparing the dope solution and forming precursor fibres by wet-spinning, followed by stabilisation and carbonisation. The present disclosure further relates to precursor fibres and carbon fibres produced using the disclosed compositions and processes.

Description

"DEVELOPMENT OF CARBON FIBRE FROM ASPHALTENE" CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from Australian Provisional Patent Application No. 2025901284 filed on 14 April 2025, the contents of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to a dope solution. In particular, the present disclosure relates to a dope solution that can be used in a process for the manufacture of carbon fibre. The present disclosure also relates to a process of manufacturing carbon fibre using the dope solution. In addition, the present disclosure relates to carbon fibre, particularly carbon fibre manufactured using the dope solution of the present disclosure.BACKGROUND

[0003] Carbon fibre is a strong, lightweight material made from thin strands of carbon atoms bonded together in a crystalline structure. It is known for its high strength-to-weight ratio, making it extremely strong yet lightweight.

[0004] Carbon fibre production is heavily reliant on polyacrylonitrile (PAN), a product of petroleum industry. Approximately, 90% of the carbon fibre manufactured is derived from polyacrylonitrile (PAN). The use of PAN based carbon fibre is limited due to the high cost of the PAN precursor material. The cost of PAN has limited carbon fibre use to high-end applications, such as defence and aviation. The global market for carbon fibre is expected to grow at a compounded annual growth rate of 9.5% in the period of 2020-2027. Therefore, identifying suitable alternative precursor material for the production of carbon fibre may reduce the cost of carbon fibre production. This could allow the carbon fibre to be utilised in industries in which it has been prohibitively expensive to date.

[0005] Development of a new class of carbon fibres using alternative precursors has the potential to reduce the cost of carbon fibre manufacture. Development of a new class of carbon fibres using alternative precursors has the potential to expand the use of carbon fibre. Development of a new class of carbon fibres using alternative precursors has the potential to make carbon fibre production more sustainable.

[0006] Therefore, it would be advantageous to develop alternative precursor materials beyond PAN for the production of carbon fibre and methods for using the same that can address the aforementioned problems and provide a viable alternative for the production of carbon fibre.SUMMARY

[0007] In a first aspect, disclosed herein is a dope solution for wet-spinning of precursors to carbon fibres, the dope solution comprising:a carbon source comprising:asphaltene, andpolyacrylonitrile;an asphaltene solvent; anda polyacrylonitrile solvent,wherein the asphaltene solvent and the polyacrylonitrile solvent are miscible.

[0008] In a second aspect, disclosed herein is a process of forming a dope solution, the process comprising:combining asphaltene and an asphaltene solvent to form an asphaltene mixture; optionally, agitating the asphaltene mixture;introducing a polyacrylonitrile solvent to the asphaltene mixture to form a dual solvent mixture;optionally, agitating the dual solvent mixture; andintroducing polyacrylonitrile to the dual solvent mixture to form the dope solution.

[0009] In a third aspect, disclosed herein is a process of forming a dope solution, the process comprising:combining asphaltene and an asphaltene solvent to form an asphaltene mixture; optionally, agitating the asphaltene mixture;introducing a polyacrylonitrile solvent to the asphaltene mixture to form a dual solvent mixture;optionally, agitating the dual solvent mixture; andintroducing polyacrylonitrile to the dual solvent mixture to form the dope solution.

[0010] In a fourth aspect, disclosed herein is a dope solution obtain from the process of the second aspect.

[0011] In a fifth aspect, disclosed herein is a precursor fibre obtained from the process of the third aspect, wherein the precursor fibre has one or more of:a diameter (pm) of between about 1 to about 35;an elongation (%) of at least about 5;a tensile strength (MPA) of at least about 50; anda tensile modulus (GPa) of at least about 3.5.

[0012] In a sixth aspect, disclosed herein is a carbon fibre obtained from the process of the third aspect, wherein the carbon material has one or more of:a diameter (pm) of between about 1 to about 35;a tensile strength (GPa) of at least about 1;a tensile modulus (GPa) of at least about 150;a doo2 (nm) of between about 0.35 to about 0.36;a Lc (nm) of between about 1.5 to about 1.7; andan ID / IG ratio of between about 0.85 to about 0.9.

[0013] The inventors of the present application have surprisingly discovered that asphaltene can be used to replace a portion of PAN as a precursor material for carbon fibre production. Further, the inventors have discovered that for in some instancesasphaltene may be used as at least a portion of the precursor material for carbon fibre production without any modification. Advantageously, this can provide up to a 35% reduction in the current market price of carbon fibre. The utilisation of asphaltene to develop carbon fibre not only offers a great value addition but also helps in reducing its environmental impact, offering a value addition to asphaltene as compared to being a petroleum waste.

[0014] Advantageously, the inventors have discovered that various types of asphaltene may be used. The asphaltene is not influenced by the type of PAN, the chemical composition of PAN, the molecular weight of PAN, and / or the method of production of PAN.

[0015] The formation of homogenous dope without any air bubbles was found to be very important to avoid developing any physical impurities in the wet-spun precursor fibre.

[0016] The fibre crystallographic alignment is generally obtained by stretching of the fibre during spinning process. Fibre stretching can only be carried out when dope is homogenous and having enough viscosity to undertake the given stretch.BRIEF DESCRIPTION OF DRAWINGS

[0017] Preferred embodiments of the present disclosure will be further described and illustrated, by way of example only, with reference to the accompanying drawings in which:

[0018] Figure 1 shows the dispersion of two samples of asphaltene (SI - left and S2 -right) is a toluene / DMSO mixture.

[0019] Figure 2 shows the dispersion of two samples of asphaltene (SI - left and S2 -right) is pyridine.

[0020] Figure 3 shows the method of preparing the dope solution.

[0021] Figure 4 shows the wet-spinning process.

[0022] Figure 5 shows the wet-spun precursor fibre made from dope solutions (DS 1 to DS3) shown in Table 1.

[0023] Figure 6 shows the mechanical performance of the 20 wt% (bottom) and 30 wt% (top) asphaltene carbon fibre.

[0024] Figure 7 shows the RAMAN analysis of the 20 wt% (bottom) and 30 wt% (top) asphaltene carbon fibre.

[0025] Figure 8 shows the XRD analysis of the 20 wt% (bottom) and 30 wt% (top) asphaltene carbon fibre.DESCRIPTION OF EMBODIMENTSGeneral terms

[0026] With regards to the definitions provided herein, unless stated otherwise, or implicit from context, the defined terms and phrases include the provided meanings. Unless explicitly stated otherwise, or apparent from context, the terms and phrases below do not exclude the meaning that the term or phrase has acquired by a person skilled in the relevant art. The definitions are provided to aid in describing particular embodiments, and are not intended to limit the claimed invention, because the scope of the invention is limited only by the claims. Furthermore, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.

[0027] All publications discussed and / or referenced herein are incorporated herein in their entirety.

[0028] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present disclosure. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in thefield relevant to the present disclosure as it existed before the priority date of each claim of this application.

[0029] Throughout this disclosure, unless specifically stated otherwise or the context requires otherwise, reference to a single step, composition of matter, group of steps or group of compositions of matter shall be taken to encompass one and a plurality (i.e., one or more) of those steps, compositions of matter, groups of steps or groups of compositions of matter. Thus, as used herein, the singular forms “a”, “an” and “the” include plural aspects unless the context clearly dictates otherwise. For example, reference to “a” includes a single as well as two or more; reference to “an” includes a single as well as two or more; reference to “the” includes a single as well as two or more and so forth.

[0030] Those skilled in the art will appreciate that the disclosure herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the disclosure includes all such variations and modifications. The disclosure also includes all of the examples, steps, features, methods, compositions, processes, referred to or indicated in this specification, individually or collectively, and any and all combinations or any two or more of said steps or features.

[0031] The term “and / or”, e.g., “X and / or Y” shall be understood to mean either “X and Y” or “X or Y” and shall be taken to provide explicit support for both meanings or for either meaning.

[0032] As used herein, the phrase “at least one of’, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of’ means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. In some cases, “at least one of item A, item B, and item C” may mean, for example and without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

[0033] As used herein, the term “about”, unless stated to the contrary, typically refers to + / - 10%, for example + / - 5%, of the designated value.

[0034] Throughout the present specification, various aspects and components of the invention can be presented in a range format. The range format is included for convenience and should not be interpreted as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range, unless specifically indicated. For example, description of a range such as from 1 to 5 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 5, from 3 to 5 etc., as well as individual and partial numbers within the recited range, for example, 1, 1.5, 2, 2.2, 3, 4, 4.6, and 5, unless where integers are required or implicit from context. This applies regardless of the breadth of the disclosed range. Where specific values are required, these will be indicated in the specification.

[0035] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0036] In the following description, reference is made to the accompanying drawings which form a part hereof, and which is shown, by way of illustration, several embodiments. It is understood that other embodiments may be utilised and structural changes or adaptions to one or more methods or processes, may be made without departing from the scope of the present disclosure.

[0037] The reference to “substantially free” generally refers to the absence of that compound or component in the composition other than any trace amounts or impurities that may be present, for example this may be an amount by volume % in the total composition of less than about 3%, 2% 1%, 0.1%, 0.01%, 0.001%, or 0.0001%.Dope solution

[0038] The present disclosure relates to a dope solution comprising asphaltene and polyacrylonitrile. The inventors have surprisingly discovered that, in various embodiments, by incorporating one or more solvents in the dope solution, the dope solution may be used for wet-spinning of precursors to carbon fibres. Advantageously, the use of asphaltene, as an alternative carbon source to replace a portion of the polyacrylonitrile in the dope solution, provides for cost savings. Further, in various embodiments, the use of asphaltene provides an environmental benefit by reducing the environmental impact, offering a value addition to asphaltene beyond it being a petroleum waste.

[0039] Disclosed herein is a dope solution for wet-spinning of precursors to carbon fibres comprising:a carbon source comprising:asphaltene, andpolyacrylonitrile;an asphaltene solvent; anda polyacrylonitrile solvent,wherein:the asphaltene solvent and the polyacrylonitrile solvent are miscible.

[0040] The inventors have discovered that through the use of a dual solvent system, wherein asphaltene is soluble in the asphaltene solvent and polyacrylonitrile is soluble in the polyacrylonitrile solvent, the two species can be combined into a single solution. This solution can be used for wet-spinning of precursors to carbon fibres.Asphaltene

[0041] Asphaltenes are a byproduct of petroleum and coal waste, and its properties depend on the method of extraction source of origin, type of impurities and their fractions. Asphaltenes are defined as the non-polar and non-volatile components of crude oil. Asphaltenes are insoluble in alkanes (normal pentane and normal heptane) but soluble in aromatics (benzene and toluene).

[0042] Asphaltenes are defined operationally as the n-heptane (C7Hie)-insoluble, toluene (G.HsCHsl-soluble component of a carbonaceous material such as crude oil, bitumen, or coal.

[0043] Asphaltenes are molecular substances that are found in crude oil, along with resins, aromatic hydrocarbons, and saturates (i.e. saturated hydrocarbons such as alkanes). Asphaltenes consist primarily of carbon, hydrogen, nitrogen, oxygen, and sulphur, as well as trace amounts of metals, for example vanadium and nickel. In general, asphaltene is the highest polar fraction of oil and contains various functional groups including but not limited to polyaromatics, aromatics, aliphatic hydrocarbons, and sulfoxides. The C:H ratio is approximately 1:1.2, depending on the asphaltene source. The high carbon fraction could make asphaltene a suitable candidate for carbon fibre precursor.Polyacrylonitrile

[0044] Polyacrylonitrile (PAN) is a synthetic, semicrystalline organic polymer resin, with the linear formula (CH2CHCN)n.

[0045] In embodiments, the polyacrylonitrile has an average molecule weight (g / mol) of about, or greater than about: 50,000, 55,000, 60,000, 65,000, 70,000, 75,000, 80,000, 85,000, 90,000, 95,000, 100,000, 105,000, 110,000, 115,000, 120,000, 125,000, 130,000, 135,000, 140,000, 145,000, 150,000, 155,000, 160,000, 165,000, 170,000, 175,000, 180,000, 185,000, 190,000, 195,000, 200,000, 205,000, 210,000, 215,000, 220,000, 225,000, 230,000, 235,000, 240,000, 245,000, 250,000, 255,000, 260,000, 265,000, 270,000, 275,000, 280,000, 285,000, 290,000, 295,000, 300,000, 305,000, 310,000, 315,000, 320,000, 325,000, 330,000, 335,000, 340,000, 345,000, 350,000, 355,000, 360,000, 365,000, 370,000, 375,000, 380,000, 385,000, 390,000, 395,000, 400,000, 405,000, 410,000, 415,000, 420,000, 425,000, 430,000, 435,000, 440,000, 445,000, 450,000, 455,000, 460,000, 465,000, 470,000, 475,000, 480,000, 485,000, 490,000, 495,000, and 500,000. In embodiments, the polyacrylonitrile has an average molecule weight (g / mol) of less than about: 500,000, 495,000, 490,000, 485,000, 480,000, 475,000, 470,000, 465,000, 460,000, 455,000, 450,000, 445,000, 440,000, 435,000,430,000, 425,000, 420,000, 415,000, 410,000, 405,000, 400,000, 395,000, 390,000, 385,000, 380,000, 375,000, 370,000, 365,000, 360,000, 355,000, 350,000, 345,000, 340,000, 335,000, 330,000, 325,000, 320,000, 315,000, 310,000, 305,000, 300,000, 295,000, 290,000, 285,000, 280,000, 275,000, 270,000, 265,000, 260,000, 255,000, 250,000, 245,000, 240,000, 235,000, 230,000, 225,000, 220,000, 215,000, 210,000, 205,000, 200,000, 195,000, 190,000, 185,000, 180,000, 175,000, 170,000, 165,000, 160,000, 155,000, 150,000, 145,000, 140,000, 135,000, 130,000, 125,000, 120,000, 115,000, 110,000, 105,000, 100,000, 95,000, 90,000, 85,000, 80,000, 75,000, 70,000, 65,000, 60,000, 55,000, 50,000. The polyacrylonitrile has an average molecule weight (g / mol) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the polyacrylonitrile has an average molecule weight (g / mol) is between about 50,000 to about 500,000, between about 70,000 to about 230,000, or between 150,000 to about 200,000.Asphaltene solvent

[0046] In embodiments, the asphaltene solvent is selected from benzene, toluene, xylene (o-, m-, p-isomers), ethylbenzene, cumene (isopropylbenzene), styrene, mesitylene (1,3,5-trimethylbenzene), pseudocumene (1,2,4-trimethylbenzene), durene (1,2,4,5-tetramethylbenzene), naphthalene, tetralin (tetrahydronaphthalene), decalin (decahydronaphthalene), phenol, chlorobenzene, bromobenzene, nitrobenzene, anisole (methoxybenzene), cresol (m-, o-, p- isomers), pyridine, quinoline, indene, biphenyl, diphenylmethane, triphenylmethane, benzyl alcohol, benzyl benzoate, diphenyl ether, phthalates (optionally, dibutyl phthalate, dimethyl phthalate), acetone, acetonitrile, dimethyl sulfoxide (DMSO), dimethylformamide (DMF), tetrahydrofuran (THF), N-methyl-2-pyrrolidone (NMP), ethyl acetate, propylene carbonate, 1,3 -di oxolane, di chloromethane (DCM), chloroform, tetrachloroethylene, trichloroethylene, 1,2-di chloroethane, chlorobenzene, dimethylacetamide (DMAc), hexamethylphosphoramide (HMPA), sulfolane, y-butyrolactone (GBL), 1,2-dimethoxy ethane (DME), N,N-diethylformamide (DEF), formamide, carbon tetrachloride, 1,1,1 -tri chloroethane, tri chlorofluoromethane (CFC-11), dichlorodifluoromethane (CFC-12), 1,2-dibromoethane, bromotrifluoromethane, and combinations thereof

[0047] In embodiments, the asphaltene solvent is selected from toluene, pyridine, chloroform, tetrahydrofuran, and combinations thereof. In embodiments, the asphaltene solvent is selected from toluene, pyridine, and combinations thereof. In embodiments, the asphaltene solvent is toluene. In embodiments, the asphaltene solvent is pyridine.Polyacrylonitrile solvent

[0048] In embodiments, the polyacrylonitrile solvent is selected from dimethyl sulfoxide (DMSO), dimethylformamide (DMF) and dimethylacetamide (DMAc), ethylene carbonate, propylene carbonate, dimethyl sulfone (DMSO2), and combinations thereof

[0049] In embodiments, the polyacrylonitrile solvent is selected from dimethyl sulfoxide (DMSO), dimethyl sulfone (DMSO2), dimethylformamide (DMF) and dimethylacetamide (DMAc), ethylene carbonate, propylene carbonate, and combinations thereof.Ratio of asphaltene to asphaltene solvent

[0050] In embodiments, the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is about, or greater than about: 1:1, 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, 1:12, 1:13, 1:14, 1:15, 1:16, 1:17, 1:18, 1:19, or 1:20. In embodiments, the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is less than about: 1:20, 1:19, 1:18, 1:17, 1:16, 1:15, 1:14, 1:13, 1:12, 1:11, 1:10, 1:9, 1:8, 1:7, 1:6, 1:5, 1:4, 1:3, 1:2, or 1:1. In embodiments, the weight ratio of the asphaltene to the asphaltene solvent in the dope solution may be in a range provided by any two of these upper and / or lower values. In embodiments, the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is in the range of between about 1 : 1 to about 1 :20. In embodiments, the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is in the range of between about 1:2 to about 1:10. In embodiments, the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is about 1:5.Dope solution composition

[0051] In embodiments, the asphaltene content in the carbon source (% w / w based on the total weight of the carbon source) is about, or greater than about: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, or 40. In embodiments, the asphaltene content in the carbon source (% w / w based on the total weight of the composition) is less than about: 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1. In embodiments, the asphaltene content in the carbon source (% w / w based on the total weight of the composition) may be in a range provided by any two of these upper and / or lower values. In embodiments, the asphaltene content in the carbon source (% w / w based on the total weight of the carbon source) is between about 1 to about 40. In embodiments, the asphaltene content in the carbon source (% w / w based on the total weight of the carbon source) is between about 5 to about 35.

[0052] In embodiments, the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) is about, or greater than about: 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99. In embodiments, the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) is less than about: 99, 98, 97, 96, 95, 94, 93, 92, 91, 90, 85, 80, 75, 70, 65, or 60. In embodiments, the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) may be in a range provided by any two of these upper and / or lower values. In embodiments, the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) is between about 60 to about 99, or between about 65 to about 95. In embodiments, the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) is between about 65 to about 95.

[0053] In embodiments, the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50. In embodiments, the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the carbonsource content in the dope solution (% w / w based on the total weight of the dope solution) may be in a range provided by any two of these upper and / or lower values. In embodiments, the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 40. In embodiments, the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is between about 5 to about 35. In embodiments, the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is between about 10 to about 30. In embodiments, the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is between about 15 to about 25.

[0054] In embodiments, the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70. In embodiments, the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) is less than about: 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) may be in a range provided by any two of these upper and / or lower values. In embodiments, the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 50. In embodiments, the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 5 to about 30.

[0055] In embodiments, the polyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70. In embodiments, the polyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) is less than about: 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the polyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) may be in a range provided by any two of these upper and / or lower values. In embodiments, thepolyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 60. In embodiments, the polyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 5 to about 50.

[0056] In embodiments, the water content (% w / w based on the total weight of the dope solution) in the dope solution in the dope solution is less than about 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.09, 0.08, 0.07, 0.06, 0.05, 0.04, 0.03, 0.02, or 0.01. In embodiments, the water content (% w / w based on the total weight of the dope solution) in the dope solution in the dope solution is less 1.

[0057] In embodiments, the dope solution is substantially free of water.Viscosity

[0058] The rheological behaviour of the dope solutions was characterised with rheometer. Test were conducted with a controlled stress single head rheometer using 25 mm parallel plates with the gap of 1.0 mm under air at atmospheric pressure. In embodiments, the viscosity (Pa.s) of the dope solution is about, or greater than about: 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, or 750. In embodiments the viscosity (Pa.s) of the dope solution is less than about: 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 200, 150, 100, 90, 80, 70, 60, 50, 45, 40, 35, 30, 25, 20, 15, 10. In embodiments, the viscosity (Pa.s) of the dope solution may be in a range provided by any two of these upper and / or lower values. In embodiments, the viscosity (Pa.s) of the dope solution is between about about 10 to about 600. In embodiments, the viscosity (Pa.s) of the dope solution is between about about 150 to about 300.Process of forming a dope solution

[0059] Disclosed herein is a process of forming a dope solution, the process comprising:combining asphaltene and an asphaltene solvent to form an asphaltene mixture; optionally, agitating the asphaltene mixture;introducing a polyacrylonitrile solvent to the asphaltene mixture to form a dual solvent mixture;optionally, agitating the dual solvent mixture; andintroducing polyacrylonitrile to the dual solvent mixture to form the dope solution.

[0060] In embodiments, there is provided a process of forming a dope solution, the process comprising:combining asphaltene and an asphaltene solvent to form an asphaltene mixture; introducing a polyacrylonitrile solvent to the asphaltene mixture to form a dual solvent mixture;introducing polyacrylonitrile to the dual solvent mixture to form the dope solution.Agitating asphaltene mixture

[0061] In embodiments, the process further comprises agitating the asphaltene mixture.

[0062] In embodiments, the agitating the asphaltene mixture is performed for a period of time (hours) of about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10. In embodiments, the agitating the asphaltene mixture is performed for a period of time (hours) of less than about: 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the agitating the asphaltene mixture is performed for a period of time (hours) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the agitating the asphaltene mixture is performed for a period of time (hours) of between about 0.1 to about 5.

[0063] In embodiments, the agitating the asphaltene mixture is by sonication.

[0064] In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) of about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) of less than about: 100, 95,90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) which may be in a range provided by any two of these upper and / or lower values. In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) of between about 5 to about 100.Agitating dual solvent mixture

[0065] In embodiments, the process further comprises agitating the dual solvent mixture.

[0066] In embodiments, the agitating the dual solvent mixture is performed for a period of time (hours) of about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10. In embodiments, the agitating the dual solvent mixture is performed for a period of time (hours) of less than about: 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the agitating the dual solvent mixture is performed for a period of time (hours) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the agitating the dual solvent mixture is performed for a period of time (hours) of between about 0.1 to about 5.

[0067] In embodiments, the agitating the dual solvent mixture is by sonication.

[0068] In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) of about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) of less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) which may be in a range provided by any two of these upper and / or lower values. In embodiments, where agitation is by sonication, the sonication is performed at a frequency (kHz) of between about 5 to about 100.Introducing with stirring

[0069] In embodiments, introducing the polyacrylonitrile solvent to the asphaltene mixture comprises stirring the asphaltene mixture.

[0070] In embodiments, introducing the polyacrylonitrile to the dual solvent mixture comprises stirring the dual solvent mixture.Process for forming a carbon fibre

[0071] Disclosed herein is a process for forming a carbon fibre, the process comprising:obtaining a dope solution as described herein;wet-spinning the dope solution to form a precursor fibre;stabilising the precursor fibre to form a stabilised precursor fibre; and carbonising the stabilised precursor fibre to form the carbon fibre, wherein the wet-spinning comprises:extruding the dope solution through a spinneret at least partially immersed in a coagulation bath to form the precursor fibre; andremoving the precursor fibre from the coagulation bath.

[0072] In embodiments, the obtaining a dope solution as described herein is achieved by the process of forming a dope solution as described herein.Spinneret

[0073] The inventors have discovered that through appropriate selection of various features of the spinneret the properties and amount of precursor fibre formed can be optimised for stabilisation and carbonisation.

[0074] In embodiments, the spinneret has a diameter (in pm) of about, or greater than about: 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, or 150. In embodiments, the spinneret has a diameter (in pm) of less than about: 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, or 50. In embodiments, the spinneret has a diameter (in pm) which is in a range provided by any two of these upper and / or lower values. In embodiments, the spinneret has adiameter (in pm) of between about 50 to about 150. In embodiments, the spinneret has a diameter (in pm) of between about 80 to about 100.

[0075] In embodiments, the spinneret has a capillary length (in pm) of about, or greater than about: 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, or 150. In embodiments, the spinneret has a capillary length (in pm) of less than about: 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, or 50. In embodiments, the spinneret has a capillary length (in pm) which is in a range provided by any two of these upper and / or lower values. In embodiments, the spinneret has a capillary length (in pm) of between about 50 to about 150. In embodiments, the spinneret has a capillary length (in pm) of between about 80 to about 100.

[0076] The spinneret comprises a number of holes through which the dope solution is extruded. In embodiments, the spinneret has a number of holes of about, or greater than about: 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, or 1500. In embodiments, the spinneret has a number of holes of less than about: 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 200, or 100. In embodiments, the spinneret has a number of holes which is in a range provided by any two of these upper and / or lower values. In embodiments, the spinneret has a number of holes of between about 100 to about 1500. In embodiments, the spinneret has a number of holes of about 800 to about 1200. In embodiments, the spinneret has a number of holes of about 1000.Fibre amount

[0077] In embodiments, the wet-spinning the dope solution to form a precursor fibre provides a number of precursor fibres that is of about, or greater than about: 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, or 2500. In embodiments, the wet-spinning the dope solution to form a precursor fibre provides a number of precursor fibres of less than about: 2500, 2400, 2300, 2200, 2100, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, 300, 200, or 100. In embodiments,the wet-spinning the dope solution to form a precursor fibre provides a number of precursor fibres which may be in a range provided by any two of these upper and / or lower values. In embodiments, the wet-spinning the dope solution to form a precursor fibre provides a number of precursor fibres of between about 100 to about 200. In embodiments the wet-spinning the dope solution to form a precursor fibre provides a number of precursor fibres of between about 500 to about 1500. In embodiments the wetspinning the dope solution to form a precursor fibre provides a number of precursor fibres of about 1000.Wet-spinning

[0078] Wet-spinning carbon fibres is a manufacturing process where a polymer solution containing carbon precursors is extruded through a spinneret into a coagulation bath, causing the polymer to solidify into fibres by removing the solvent, creating a carbon fibre precursor that can be further processed to produce high-strength carbon fibres. The inventors have discovered that the process conditions of the wet-spinning process can be optimised to assist in the aligned crystallographic structure of precursor fibre, which in turn can provide for a carbon fibre with desirable properties, for example, diameter, and / or strength.

[0079] The extrusion speed refers to the rate at which the polymer solution is pushed through the spinneret. In embodiments, the extruding of the dope solution through the spinneret is performed at a speed (m / min) of about, or greater than about: 0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, or 1. In embodiments, the extruding of the dope solution though the spinneret is performed at a speed (m / min) of less than about: 1, 0.95, 0.90, 0.85, 0.80, 0.75, 0.70, 0.65, 0.60, 0.55, 0.50, 0.45, 0.40, 0.35, 0.30, 0.25, 0.20, 0.15, 0.10, or 0.05. In embodiments, the extruding of the dope solution though the spinneret is performed at a speed (m / min) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the extruding of the dope solution though the spinneret is performed at a speed (m / min) of between about 0.1 to 1. In embodiments, the extruding of the dope solution though the spinneret is performed at a speed (m / min) of between about 0.25 to 0.75.

[0080] In embodiments, the dope solution prior to wet-spinning is at a temperature (°C) of about, or greater than about: 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, the dope solution prior to wet-spinning is at a temperature (°C) of less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40. In embodiments, the dope solution prior to wet-spinning is at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the dope solution prior to wet-spinning is at a temperature (°C) of between about 40 to about 100. In embodiments, the dope solution prior to wet-spinning is at a temperature (°C) of between about 40 to about 80. In embodiments, the dope solution prior to wet-spinning is at a temperature (°C) of between about 55 to about 65.

[0081] In embodiments, the wet-spinning the dope solution is performed at a temperature (°C) of about, or greater than about: 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, the wet-spinning the dope solution is performed at a temperature (°C) of less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40. In embodiments, the wet-spinning the dope solution is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the wet-spinning the dope solution at a temperature (°C) of between about 40 to about 100. In embodiments, the wet-spinning the dope solution is performed at a temperature (°C) of between about 40 to about 80. In embodiments, the wet-spinning the dope solution is performed at a temperature (°C) of between about 55 to about 65.Coagulation bath

[0082] In embodiments, the coagulation bath is at a temperature (°C) of about, or greater than about: 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, the coagulation bath is at a temperature (°C) of less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40. In embodiments, the coagulation bath is at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the coagulation bath is at a temperature (°C) of between about 40 to about 100. In embodiments, the coagulation bath is at a temperature (°C) of between about 60 to about 95.

[0083] In embodiments, the coagulation bath comprises water, a coagulation bath organic solvent, or a combination thereof.

[0084] In embodiments, the coagulation bath organic solvent is selected from dimethyl sulfoxide, dimethylformamide, and combinations thereof. In embodiments, the coagulation bath organic solvent is dimethyl sulfoxide.

[0085] In embodiments, the water content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is about, or greater than about: 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, or 60. In embodiments, the water content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is less than about: 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10. In embodiments, the water content in the coagulation bath (% w / w based on the total weight of the coagulation bath) may be in a range provided by any two of these upper and / or lower values. In embodiments, the water content in the coagulation bath is between about 30 to about 50.

[0086] In embodiments, the dimethyl sulfoxide content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is about, or greater than about: 40, 45, 50, 55, 60, 65, 70, 75, 80, 85 or 90. In embodiments, the dimethyl sulfoxide content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is less than about: 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40. In embodiments, the dimethyl sulfoxide content in the coagulation bath (% w / w based on the total weight of the coagulation bath) may be in a range provided by any two of these upper and / or lower values. In embodiments, the dimethyl sulfoxide content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is between about 50 to about 70.

[0087] In embodiments, the coagulation bath organic solvent content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is about, or greater than about: 40, 45, 50, 55, 60, 65, 70, 75, or 80. In embodiments, the coagulation bath organic solvent content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40. In embodiments, the coagulation bath organic solvent content in the coagulation bath (% w / w based on thetotal weight of the coagulation bath) may be in a range provided by any two of these upper and / or lower values. In embodiments, the coagulation bath organic solvent content in the coagulation bath (% w / w based on the total weight of the coagulation bath) is between about 50 to about 70.Removal of precursor fibre from coagulation bath

[0088] In wet-spinning removing the precursor fibre from the coagulation bath refers to the newly formed fibre is pulled out of the coagulation bath and onto, for example, a rotating roller. In embodiments, the removing the precursor fibre from the coagulation bath is performed by rotating rollers. In embodiment, the removing the precursor fibre from the coagulation bath is performed by steam rotating rollers or hot godet rotating rollers.

[0089] In embodiments, the removing the precursor fibre from the coagulation bath is performed at a speed (m / min) of about, or greater than about: 0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 In embodiments, the removing the precursor fibre from the coagulation bath is performed at a speed (m / min) of less than about: 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.95, 0.90, 0.85, 0.80, 0.75, 0.70, 0.65, 0.60, 0.55, 0.50, 0.45, 0.40, 0.35, 0.30, 0.25, 0.20, 0.15, 0.10, or 0.05. In embodiments, the removing the precursor fibre from the coagulation bath is performed at a speed (m / min) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the removing the precursor fibre from the coagulation bath is performed at a speed (m / min) of between about 0.5 to 2.

[0090] In embodiments, the removing the precursor fibre from the coagulation bath is performed at a temperature (°C) of about, or greater than about: 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80. In embodiments, the removing the precursor fibre from the coagulation bath is performed at a temperature (°C) of less than about: 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25 or 20. In embodiments, the removing the precursor fibre from the coagulation bath is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the removing theprecursor fibre from the coagulation bath is performed at a temperature (°C) of between about 20 to about 80.Stretchins

[0091] Fibres are stretched during production to align the polymer chains, improving the strength and stiffness of the fibres by creating stronger molecular bonds. This alignment enhances the mechanical properties of the fibres, making them more resilient. Additionally, stretching reduces the fibre diameter, ensuring uniformity and achieving the desired thickness for the final carbon fibre. In embodiments, the wet-spinning further comprises stretching the precursor fibre prior to stabilising the precursor fibre.

[0092] In embodiments, the wet spinning further comprises applying a draw ratio to the precursor fibre prior to stabilising the precursor fibre. In embodiments, the draw ratio applied to the precursor fibre during wet-spinning is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50. In embodiments, the draw ratio applied to the precursor fibre during wet-spinning (in N) is less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the draw ratio applied to the precursor fibre during wet-spinning may be in a range provided by any two of these upper and / or lower values. In embodiments, the draw ratio applied to the precursor fibre during wet-spinning is between about 0.1 to about 50. In embodiments, the tension applied to the precursor fibre during wet-spinning (in N) is between about 10 to about 20.Washins

[0093] Fibre washing is typically done after the spinning and before the stabilisation process. After the fibres are spun and any spin-finishing agents or lubricants have been applied, washing helps remove any residual chemicals, solvents, or impurities. This ensures that the fibres are clean and free of contaminants before they undergo the stabilisation and carbonisation processes. In embodiments, the wet-spinning further comprises washing the precursor fibre prior to stabilising the precursor fibre.S in-finishing

[0094] Spin-finishing is typically done immediately after the fibre has been spun and before it undergoes any further processing, such as stabilisation, carbonisation, or weaving. It is applied right after the fibres are formed, while they are still in a wet or semi-solid state, to reduce friction and prevent damage during handling.

[0095] In embodiments, the wet-spinning further comprises spin-finishing the precursor fibre prior to stabilising the precursor fibre, wherein the spin-finishing comprises:contacting the precursor fibre with a spin-finish solution.

[0096] In embodiments the spin-finish solution comprises an oil In embodiments the spin-finish solution comprises a silicon oil.

[0097] In embodiments, the oil content in the spin-finish solution (% w / w based on the total weight of the spin-finish solution) is about, or greater than about: : 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10. In embodiments, the oil content in the spin-finish solution (% w / w based on the total weight of the spin-finish solution) is less than about: 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.. In embodiments, the oil content in the spin-finish solution (% w / w based on the total weight of the spin-finish solution) may be in a range provided by any two of these upper and / or lower values. In embodiments, the oil content in the spin-finish solution (% w / w based on the total weight of the spin-finish solution) is between about 1 to about 10.Dryins

[0098] Fibres are dried to remove any residual moisture that may affect their properties during subsequent processing steps. Excess moisture can interfere with the stability of the fibres, especially during high-temperature treatments like stabilisation and carbonisation. In embodiments, the wet-spinning further comprises drying the precursor fibre prior to stabilising the precursor fibre.Stabilising

[0099] Stabilisation involves heating the freshly formed fibres in an oxygen-rich environment at moderate temperatures. Stabilisation helps prevent the fibres from melting during the subsequent high-temperature treatments. Stabilisation induces crosslinking in the carbon source creating a more thermally stable structure.

[0100] In embodiments, the stabilising the precursor fibre is performed at a temperature (°C) of about, or greater than about: 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, or 350. In embodiments, the stabilising the precursor fibre is performed at a temperature (°C) of less than about: 350, 340, 330, 320, 310, 300, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, or 150. In embodiments, the stabilising the precursor fibre is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the stabilising the precursor fibre is performed at a temperature (°C) of between about 150 to about 350. In embodiments, the stabilising the precursor fibre is performed at a temperature (°C) of between about 200 to about 300.

[0101] In embodiments, the stabilising the precursor fibre is performed for a period of time (mins) of about, or greater than about: 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, or 180. In embodiments, the stabilising the precursor fibre is performed for a period of time (mins) of less than about: 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 20, or 10. In embodiments, the stabilising the precursor fibre is performed for a period of time (mins) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the stabilising the precursor fibre is performed for a period of time (mins) of between about 10 to about 180. In embodiments, the stabilising the precursor fibre is performed for a period of time (mins) of between about 20 to about 120.

[0102] In embodiments, the stabilising the precursor fibre further comprises applying tension (in N)the precursor fibre. In embodiments, the stabilising the precursor fibre further comprises applying a tension to the precursor fibre. In embodiments, the tension applied to the precursor fibre during stabilisation (in N) is about, or greater than about:100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, or 300. In embodiments, the tension applied to the precursor fibre during stabilisation (in N) is less than about: 300, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, or 100. In embodiments, the tension applied to the precursor fibre during stabilisation (in N) may be in a range provided by any two of these upper and / or lower values. In embodiments, the tension applied to the precursor fibre during stabilisation (in N) is between about 100 to about 300. In embodiments, the tension applied to the precursor fibre during stabilisation (in N) is between about 150 to about 250.

[0103] In embodiments, the stabilising the precursor fibre is performed in two or more stabilising stages.Carbonising

[0104] Carbonisation involves heating the stabilised fibres to high temperatures in a furnace with and inert environment, for example an environment with no oxygen. Carbonisation removes non-carbon elements leaving behind almost pure carbon fibre.

[0105] In embodiments, the carbonising the stabilised precursor fibre is performed at a temperature (°C) of about, or greater than about: 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, or 2500. In embodiments, the carbonising the stabilised precursor fibre is performed at a temperature (°C) of less than about: 2500, 2400, 2300, 2200, 2100, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, 900, 800, 700, 600, 500, 400, or 300. In embodiments, the carbonising the stabilised precursor fibre is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the carbonising the stabilised precursor fibre is performed at a temperature (°C) of between about 300 to about 2500. In embodiments, the carbonising the stabilised precursor fibre is performed at a temperature (°C) of between about 300 to about 1800.

[0106] In embodiments, the carbonising the stabilised precursor fibre is performed for a period of time (mins) of about, or greater than about: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, or 120. In embodiments, the carbonising the stabilised precursor fibre is performed for a period of time (mins) of less than about: 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5. In embodiments, the carbonising the stabilised precursor fibre is performed for a period of time (mins) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the carbonising the stabilised precursor fibre is performed for a period of time (mins) of between about 5 to about 60.

[0107] In embodiments, the carbonising the stabilised precursor fibre comprises a low temperature carbonising and a high temperature carbonising.

[0108] In embodiments, the low temperature carbonising is performed at a temperature (°C) of about, or greater than about: 300, 400, 500, 600, 700, 800, or 900. In embodiments, the low temperature carbonising is performed at a temperature (°C) of less than about: 900, 800, 700, 600, 500, 400, or 300. In embodiments, the low temperature carbonising is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the low temperature carbonising is performed at a temperature (°C) of between about 300 to about 900.

[0109] In embodiments, the low temperature carbonising performed in two or more low temperature carbonising stages.

[0110] In embodiments, the high temperature carbonising is performed at a temperature (°C) of about, or greater than about: 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, or 2500. In embodiments, the high temperature carbonising is performed at a temperature (°C) of less than about: 2500, 2400, 2300, 2200, 2100, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, 1000, or 900. In embodiments, the high temperature carbonising is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the high temperature carbonising is performed at atemperature (°C) of between about 900 to about 2500. In embodiments, the high temperature carbonising is performed at a temperature (°C) of between about 900 to about 1800.

[0111] In embodiments, the carbonisation of the stabilised precursor fibre further comprises applying a tension to the stabilised precursor fibre. In embodiments, the tension applied to the stabilised precursor fibre during carbonisation (in N) is about, or greater than about: 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, or 400. In embodiments, the tension applied to the stabilised precursor fibre during carbonisation (in N) is less than about: 400, 390, 380, 370, 360, 350, 340, 330, 320, 310, 300, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, or 100. In embodiments, the tension applied to the stabilised precursor fibre during carbonisation (in N) may be in a range provided by any two of these upper and / or lower values. In embodiments, the tension applied to the stabilised precursor fibre during carbonisation (in N) is between about 0.1 to about 50. In embodiments, the tension applied to the stabilised precursor fibre during carbonisation (in N) is between about 100 to about 400, or between about 130 to about 350.

[0112] In embodiments, the high temperature carbonising performed in two or more high temperature carbonising stages.Drying of asphlatene

[0113] The purpose of drying is primarily the removal of absorbed moisture from the asphaltene surface without changing their functionality and structure. The inventors have found the asphaltene is sensitive to the drying environment and drying can cause some change to functional groups. Therefore, the appropriate selection of the environment becomes essential for future modification of asphaltene. In embodiments, the process further comprises drying the asphaltene prior to forming the dope solution.

[0114] Drying may be performed with any suitable method known in the art. In embodiments, drying the asphaltene is performed in air, nitrogen, or under vacuum. Inembodiments, drying the asphaltene is performed in nitrogen, or under vacuum. In embodiments, drying the asphaltene is performed in nitrogen. In embodiments, drying the asphaltene is performed under vacuum. The inventors have identified that vacuum drying or nitrogen drying was more effective as under these conditions there was less change to the core and surface properties of the asphaltene.

[0115] In embodiments, the drying the asphaltene is performed at an absolute pressure (bar) of about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1. In embodiments, the drying the asphaltene is performed at an absolute pressure (bar) of less than about: 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the drying the asphaltene is performed at an absolute pressure (bar) may be in a range provided by any two of these upper and / or lower values. In embodiments, the drying the asphaltene is performed at an absolute pressure (bar) of between about 0.1 to about 1.

[0116] In embodiments, the drying the asphaltene is performed for a period of time (hours) of about, or greater than about: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, or 24. In embodiments, the drying the asphaltene is performed for a period of time (hours) of less than about: 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1. In embodiments, the drying the asphaltene is performed for a period of time (hours) may be in a range provided by any two of these upper and / or lower values. In embodiments, the drying the asphaltene is performed for a period of time (hours) of between about 1 to about 24. In embodiments, the drying the asphaltene is performed for a period of time (hours) of between about 6 to about 18.

[0117] In embodiments, the drying the asphaltene is performed at a temperature (°C) of about, or greater than about: 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, the drying the asphaltene is performed at a temperature (°C) of less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40. In embodiments, the drying the asphaltene is performed at a temperature (°C) which may be in a range provided by any two of these upper and / or lower values. In embodiments, the drying the asphaltene is performed at a temperature (°C) of between about 40 to about 100. In embodiments,the drying the asphaltene is performed at a temperature (°C) of between about 60 to about 95.Filtering and degassing

[0118] In embodiments, the process further comprise filtering the dope solution prior to the wet-spinning the dope solution.In embodiments, the process further comprises degassing the dope solution prior to the wet-spinning the dope solution.Product by processPrecursor fibre

[0119] Disclosed herein is a precursor fibre obtained from the process for forming a carbon fibre as described herein.

[0120] In embodiments, there is provided a precursor fibre obtained from the process as described herein, wherein the carbon material has one or more ofa diameter (pm) of between about 1 to about 35;an elongation (%) of at least about 5;a tensile strength (MPa) of at least about 50; anda tensile modulus (GPa) of at least about 3.5.

[0121] In embodiments, the diameter (pm) of the precursor fibre is about, or greater than about: 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, the diameter (pm) of the precursor fibre is less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, In embodiments, the diameter (pm) of the precursor fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the diameter (pm) of the precursor fibre is between about 0.1 to about 100, or between about 1 to about 35.

[0122] In embodiments, the elongation (%) of the precursor fibre is about, or greater than about: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50. In embodiments,the elongation (%) of the precursor fibre is less than about: 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1. In embodiments, the elongation (%) of the precursor fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the elongation (%) of the precursor fibre is between about 1 to about 50, or between about 5 to about 20. In embodiments, the elongation (%) of the precursor fibre is at least about 5.

[0123] In embodiments, the tensile strength (MPa) of the precursor fibre is about, or greater than about: 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, or 500. In embodiments, the tensile strength (MPa) of the precursor fibre is less than about: 500, 450, 400, 350, 300, 250, 200, 150, 100, 90, 80, 70, 60, 50, 45, 40, 35, 30, 25, 20, 15, or 10. In embodiments, the tensile strength (MPa) of the precursor fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the tensile strength (MPa) of the precursor fibre is between about 10 to about 500, or between about 50 to about 500. In embodiments, the tensile strength (MPa) of the precursor fibre is at least about 50.

[0124] In embodiments, the tensile modulus (GPa) of the precursor fibre is about, or greater than about: 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10, 15, or 20. In embodiments, the tensile modulus (GPa) of the precursor fibre is less than about: 20, 15, 10, 9.5, 9.0, 8.5, 8.0, 7.5, 7.0, 6.5, 6.0, 5.5, 5.0, 4.5, 4.0, 3.5, 3.0, 2.5, 2.0, 1.5, 1.0, or 0.5. In embodiments, the tensile modulus (GPa) of the precursor fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the tensile modulus (GPa) of the precursor fibre is between about 0.5 to about 20, or between about 3.5 to about 20. In embodiments, the tensile modulus (GPa) of the precursor fibre is at least about 3.5.Carbon fibre

[0125] Disclosed herein is a carbon fibre obtained from the process for forming a carbon fibre described herein.

[0126] In embodiments, there is provided a carbon fibre obtained from the process described herein, wherein the carbon material has one or more ofa diameter (pm) of between about 1 to about 35;a tensile strength (GPa) of at least about 1;a tensile modulus (GPa) of at least about 150;a doo2 (nm) of between about 0.35 to about 0.36;a Lc (nm) of between about 1.5 to about 1.7; andan ID / IG ratio of between about 0.85 to about 0.9.

[0127] In embodiments, the diameter (pm) of the carbon fibre is about, or greater than about: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100. In embodiments, the diameter (pm) of the carbon fibre is less than about: 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1. In embodiments, the diameter (pm) of the carbon fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the diameter (pm) of the carbon fibre is between about 0.1 to about 100, or between about 1 to about 35.

[0128] In embodiments, the tensile strength (GPa) of the carbon fibre is about, or greater than about: 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10, 15, or 20. In embodiments, the tensile strength (GPa) of the carbon fibre is less than about: 20, 15, 10, 9.5, 9.0, 8.5, 8.0, 7.5, 7.0, 6.5, 6.0, 5.5, 5.0, 4.5, 4.0, 3.5, 3.0, 2.5, 2.0, 1.5, 1.0, or 0.5. In embodiments, the tensile strength (GPa) of the carbon fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the tensile strength (GPa) of the carbon fibre is between about 0.5 to about 20, or between about 1 to about 20. In embodiments, the tensile strength (GPa) of the carbon fibre is at least about 1.

[0129] In embodiments, the tensile modulus (GPa) of the carbon fibre is about, or greater than about: 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 750, 1000, 1500, or 2000. In embodiments, the tensile modulus (GPa) of the carbon fibre is less than about: 2000, 1500, 1000, 750, 500, 450, 400, 350, 300, 250, 200, 150, 100, 90,80, 70, 60, or 50. In embodiments, the tensile modulus (GPa) of the carbon fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the tensile modulus (GPa) of the carbon fibre is between about 50 to about 2000, or between about 150 to about 2000. In embodiments, the tensile modulus (GPa) of the carbon fibre is at least about 1500.

[0130] In embodiments, the dotn (nm) of the carbon fibre is about, or greater than about: 0.34, 0.341, 0.342, 0.343, 0.344, 0.345, 0.346, 0.347, 0.348, 0.349, 0.35, 0.351, 0.352, 0.353, 0.354, 0.355, 0.356, 0.357, 0.358, 0.359, 0.36, 0.361, 0.362, 0.363, 0.364, 0.365, 0.366, 0.367, 0.368, 0.369, or 0.37. In embodiments, the dotn (nm) of the carbon fibre is less than about: 0.37, 0.369, 0.368, 0.367, 0.366, 0.365, 0.364, 0.363, 0.362, 0.361, 0.36, 0.359, 0.358, 0.357, 0.356, 0.355, 0.354, 0.353, 0.352, 0.351, 0.35, 0.349, 0.348, 0.347, 0.346, 0.345, 0.344, 0.343, 0.342, 0.341, or 0.34. In embodiments, the dotn (nm) of the carbon fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the dotn (nm) of the carbon fibre is between about 0.34 to about 0.37, or between about 0.35 to about 0.36.

[0131] In embodiments, the Lc (nm) of the carbon fibre is about, or greater than about: 1.4, 1.41, 1.42, 1.43, 1.44, 1.45, 1.46, 1.47, 1.48, 1.49, 1.5, 1.51, 1.52, 1.53, 1.54, 1.55, 1.56, 1.57, 1.58, 1.59, 1.6, 1.61, 1.62, 1.63, 1.64, 1.65, 1.66, 1.67, 1.68, 1.69, 1.7, 1.71, 1.72, 1.73, 1.74, 1.75, 1.76, 1.77, 1.78, 1.79, or 1.8. In embodiments, theLc (nm) of the carbon fibre is less than about: 1.8, 1.79, 1.78, 1.77, 1.76, 1.75, 1.74, 1.73, 1.72, 1.71, 1.7, 1.69, 1.68, 1.67, 1.66, 1.65, 1.64, 1.63, 1.62, 1.61, 1.6, 1.59, 1.58, 1.57, 1.56, 1.55, 1.54, 1.53, 1.52, 1.51, 1.5, 1.49, 1.48, 1.47, 1.46, 1.45, 1.44, 1.43, 1.42, 1.41, or 1.4. In embodiments, the Lc (nm) of the carbon fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the Lc (nm) of the carbon fibre is between about 1.4 to about 1.8, or between about 1.5 to about 1.7.

[0132] In embodiments, the ID / IG ratio of the carbon fibre is about, or greater than about: 0.8, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.9, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99. In embodiments, the ID / IG ratio of the carbon fibre is less than about: 0.99, 0.98, 0.97, 0.96, 0.95, 0.94, 0.93, 0.92, 0.91, 0.9, 0.89, 0.88, 0.87, 0.86,0.85, 0.84, 0.83, 0.82, 0.81, 0.8. In embodiments, the ID / IG ratio of the carbon fibre may be in a range provided by any two of these upper and / or lower values. In embodiments, the ID / IG ratio of the carbon fibre is between about 0.8 to about 0.99, or between about 0.85 to about 0.9.Dope solution

[0133] Disclosed herein is a dope solution obtained from the process of forming a dope solution as described herein.

[0134] In embodiments, there is provided a dope solution as described herein obtained from the process of forming a dope solution as described herein.

[0135] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.EXAMPLE EMBODIMENTS

[0136] The present disclosure may be described by one of more of the following example embodiments.

[0137] 1. A dope solution for wet-spinning of precursors to carbon fibres, the dope solution comprising:a carbon source comprising:asphaltene, andpolyacrylonitrile;an asphaltene solvent; andpolyacrylonitrile solvent,wherein the asphaltene solvent and the polyacrylonitrile solvent are miscible.

[0138] 2. The dope solution of example embodiment 1, wherein the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is in the range of between about 1 : 1 to about 1 :20, between about 1 :2 to about 1 : 10, or about 1:5.

[0139] 3. The dope solution of example embodiment 1 or example embodiment 2, wherein the asphaltene content in the carbon source (% w / w based on the total weight of the carbon source) is between about 1 to about 40, or between about 5 to about 35.

[0140] 4. The dope solution according to any one of example embodiments 1 to 3, wherein the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) is between about 60 to about 99, or between about 65 to about 95.

[0141] 5. The dope solution according to any one of example embodiments 1 to 4, wherein the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 40, or between about 15 to about 25.

[0142] 6. The dope solution according to any one of example embodiments 1 to 5, wherein the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 50, or between about 5 to about 30.

[0143] 7. The dope solution according to any one of example embodiments 1 to 6, wherein the polyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 60, or between about 5 to about 50.

[0144] 8. The dope solution according to any one of example embodiments 1 to 7, wherein the asphaltene solvent is selected from benzene, toluene, xylene (o-, m-, p-isomers), ethylbenzene, cumene (isopropylbenzene), styrene, mesitylene (1,3,5-trimethylbenzene), pseudocumene (1,2,4-trimethylbenzene), durene (1, 2,4,5-tetramethylbenzene), naphthalene, tetralin (tetrahydronaphthalene), decalin(decahydronaphthalene), phenol, chlorobenzene, bromobenzene, nitrobenzene, anisole (methoxybenzene), cresol (m-, o-, p- isomers), pyridine, quinoline, indene, biphenyl, diphenylmethane, triphenylmethane, benzyl alcohol, benzyl benzoate, diphenyl ether, phthalates (optionally, dibutyl phthalate, dimethyl phthalate), acetone, acetonitrile, dimethyl sulfoxide (DMSO), dimethylformamide (DMF), tetrahydrofuran (THF), N-methyl-2-pyrrolidone (NMP), ethyl acetate, propylene carbonate, 1,3 -di oxolane, di chloromethane (DCM), chloroform, tetrachloroethylene, trichloroethylene, 1,2-di chloroethane, chlorobenzene, dimethylacetamide (DMAc), hexamethylphosphoramide (HMPA), sulfolane, y-butyrolactone (GBL), 1,2-dimethoxy ethane (DME), N,N-diethylformamide (DEF), formamide, carbon tetrachloride, 1,1,1 -tri chloroethane, tri chlorofluoromethane (CFC-11), dichlorodifluoromethane (CFC-12), 1,2-dibromoethane, bromotrifluoromethane, and combinations thereof

[0145] 9. The dope solution according to any one of example embodiments 1 to 8, wherein the asphaltene solvent is selected from toluene, pyridine, chloroform, tetrahydrofuran, and combinations thereof.

[0146] 10. The dope solution according to any one of example embodiments 1 to 9, wherein the polyacrylonitrile solvent is selected from dimethyl sulfoxide (DMSO), dimethylformamide (DMF) and dimethylacetamide (DMAc), ethylene carbonate, propylene carbonate, dimethyl sulfone (DMSO2), and combinations thereof

[0147] 11. The dope solution according to any one of example embodiments 1 to 10, wherein the polyacrylonitrile solvent is selected from dimethyl sulfoxide (DMSO), dimethyl sulfone (DMSO2), dimethylformamide (DMF) and dimethylacetamide (DMAc), ethylene carbonate, propylene carbonate, and combinations thereof.

[0148] 12. The dope solution according to any one of example embodiments 1 to 11, wherein the water content (% w / w) in the dope solution is less than about 1.

[0149] 13. The dope solution according to any one of example embodiments 1 to 12, wherein the dope solution is substantially free of water.

[0150] 14. The dope solution according to any one of example embodiments 1 to 12, wherein the molecular weight (g / mol) of polyacrylonitrile is between about 70000 to about 500000, or between about 150000 to about 200000.

[0151] 14. The dope solution according to any one of example embodiments 1 to 12, wherein the viscosity (Pa.s) of the dope solution is between about 10 to about 600, or between 150 to about 300.

[0152] 15. A process of forming a dope solution, the process comprising:combining asphaltene and an asphaltene solvent to form an asphaltene mixture; optionally, agitating the asphaltene mixture;introducing a polyacrylonitrile solvent to the asphaltene mixture to form a dual solvent mixture;optionally, agitating the dual solvent mixture; andintroducing polyacrylonitrile to the dual solvent mixture to form the dope solution.

[0153] 16. The process of example embodiment 15, wherein the agitating the asphaltene mixture is by sonication.

[0154] 17. The process of example embodiment 15 or example embodiment 16, wherein the agitating the dual solvent mixture is by sonication.

[0155] 18. The process according to any one of example embodiments 15 to 17, wherein the agitating the asphaltene mixture is performed for a period of time (hours) of between about 0.1 to about 5.

[0156] 19. The process according to any one of example embodiments 15 to 18, wherein the agitating the dual solvent mixture is performed for a period of time (hours) of between about 0.1 to about 5.

[0157] 20. The process according to any one of example embodiments 15 to 19, introducing the polyacrylonitrile solvent to the asphaltene mixture comprises stirring the asphaltene mixture.

[0158] 21. The process according to any one of example embodiments 15 to 20, introducing the polyacrylonitrile to the dual solvent mixture comprises stirring the dual solvent mixture.

[0159] 22. The process according to any one of example embodiments 15 to 21, wherein the dope solution is a dope solution according to any one of example embodiments 1 to 14.

[0160] 23. A process for forming a carbon fibre, the process comprising:obtaining a dope solution of any one of example embodiments 1 to 14; wet-spinning the dope solution to form a precursor fibre;stabilising the precursor fibre to form a stabilised precursor fibre; and carbonising the stabilised precursor fibre to form the carbon fibre, wherein the wet-spinning comprises:extruding the dope solution through a spinneret at least partially immersed in a coagulation bath to form the precursor fibre; andremoving the precursor fibre from the coagulation bath.

[0161] 24. The process of example embodiment 23, wherein the process further comprises drying the asphaltene prior to forming the dope solution.

[0162] 25. The process of example embodiment 23 or example embodiment 24, wherein the wet-spinning the dope solution is performed at a temperature (°C) of between about 40 to about 80, or between about 55 to about 65.

[0163] 26. The process according to any one of example embodiments 23 to 25, wherein the process further comprise filtering the dope solution prior to the wet-spinning the dope solution.

[0164] 27. The process according to any one of example embodiments 23 to 26, wherein the process further comprises degassing the dope solution prior to the wetspinning the dope solution.

[0165] 28. The process of any one of example embodiments 23 to 27, wherein the coagulation bath is at a temperature (°C) of between about 40 to about 80, or between about 55 to about 65.

[0166] 29. The process of any one of example embodiments 23 to 28, wherein the extruding of the dope solution though the spinneret is performed at a speed (m / min) of between about 0.1 to 1, or between about 0.25 to 0.75.

[0167] 30. The process according to any one of example embodiments 23 to 29, wherein the removing the precursor fibre from the coagulation bath is performed at a speed (m / min) of between about 0.5 to 2.

[0168] 31. The process according to any one of example embodiments 23 to 30, wherein the wet-spinning further comprises stretching the precursor fibre prior to stabilising the precursor fibre.

[0169] 32. The process according to any one of example embodiments 23 to 31, wherein the wet-spinning further comprises washing the precursor fibre prior to stabilising the precursor fibre.

[0170] 33. The process according to any one of example embodiments 23 to 32, wherein the wet-spinning further comprises spin-finishing the precursor fibre prior to stabilising the precursor fibre, wherein the spin-finishing comprises:contacting the precursor fibre with a spin-finish solution.

[0171] 34. The process according to any one of example embodiments 23 to 33, wherein the wet-spinning further comprises drying the precursor fibre prior to stabilising the precursor fibre.

[0172] 35. The process according to any one of example embodiments 23 to 34, wherein the stabilising the precursor fibre is performed in two or more stabilising stages.

[0173] 36. The process according to any one of example embodiments 23 to 35, wherein the stabilising the precursor fibre is performed at a temperature (°C) of between about 200 to about 300.

[0174] 37. The process according to any one of example embodiments 23 to 36, wherein the stabilising the precursor fibre is performed for a period of time (mins) of between about 20 to about 120.

[0175] 38. The process according to any one of example embodiments 23 to 37, wherein the carbonising the stabilised precursor fibre is performed at a temperature (°C) of between about 300 to about 1800.

[0176] 39. The process according to any one of example embodiments 23 to 38, wherein the carbonising the stabilised precursor fibre is performed for a period of time (mins) of between about 5 to about 60.

[0177] 40. The process according to any one of example embodiments 23 to 39, wherein the carbonising the stabilised precursor fibre comprises a low temperature carbonising and a high temperature carbonising.

[0178] 41. The process of example embodiment 40, wherein the low temperature carbonising is performed at a temperature (°C) of between about 300 to about 900.

[0179] 42. The process of example embodiment 40 or example embodiment 41, wherein the high temperature carbonising is performed at a temperature (°C) of between about 900 to about 1800.

[0180] 43. The process according to any one of example embodiments 40 to 42, wherein the low temperature carbonising performed in two or more low temperature carbonising stages.

[0181] 44. The process according to any one of example embodiments 40 to 43, wherein the high temperature carbonising performed in two or more high temperature carbonising stages.

[0182] 45. A dope solution obtained from the process of any one of example embodiments 15 to 22.

[0183] 46. A precursor fibre obtained from the process of any one of example embodiments 23 to 44, wherein the precursor fibre has one or more of:a diameter (pm) of between about 1 to about 35;an elongation (%) of at least about 5;a tensile strength (MPA) of at least about 50; anda tensile modulus (GPa) of at least about 3.5.

[0184] 47. A carbon fibre obtained from the process of any one of example embodiments 23 to 44, wherein the carbon material has one or more of:

[0185] a diameter (pm) of between about 1 to about 35;

[0186] a tensile strength (GPa) of at least about 1;

[0187] a tensile modulus (GPa) of at least about 150;

[0188] a doo2 (nm) of between about 0.35 to about 0.36;

[0189] a Lc (nm) of between about 1.5 to about 1.7; and

[0190] an ID / IG ratio of between about 0.85 to about 0.9.EXAMPLESAsphaltene samples

[0191] Two samples of asphaltene (SI and S2) of asphaltene were prepared.Details of SI

[0192] Bitumen was mixed with water, then an n-alkane mixture was added to precipitate asphaltene. Asphaltene was removed as suspension in water. The sample was then dried to obtain SI, which was the dried asphaltene-rich fraction. SI comprised 80.0% carbon by mass with a 74 % by weight insoluble in pentane and 66 % by weight insoluble in heptane.Details of S2

[0193] S2 was obtained from athabasca bitumen. Thermal cracking was performed followed by separation by mixing with an n-alkane mixture to precipitate asphaltene. The S2 sample is the asphaltene-rich bottoms or pitch stream from the solvent separation step. S2 comprised 83.3% carbon by mass with a 89.7% by weight insoluble in pentane and 37.9% by weight insoluble in heptane.Asphaltene solubility

[0194] SI and S2 were dissolved in toluene. SI and S2 were dissolved in pyridine. SI and S2 were both observed to be soluble in both toluene and pyridine. After dissolution DMSO was added. When DMSO was added to the toluene solution, SI showed phase separation. This phenomenon was not observed in the case of the S2 toluene solution, see Figure 1. SI and S2 was found to be fully soluble in pyridine, see Figure 2. No phase separation was observed for SI and S2 when DMSO was added to the pyridine solutions. Therefore, S2 was selected as the to prepare dope solutions using both toluene and pyridine as the asphaltene solvent.Dope solution

[0195] The dope solution preparation was conducted as per the process shown in Figure 3. S2 was dissolved in toluene or pyridine solvents and agitated by sonication for 1 hour. DMSO was added to each sample while stirring the solution. The solutions were furtheragitated by sonication for 1 hour. Finally, PAN was added to each sample while stirring the solution. Various weight fraction of S2 to PAN were included in different dope solution experiments, such that dope solutions comprised carbon sources (asphaltene and PAN) which comprises 10 %w / w, 20 %w / w, 30 %w / w, and 40 %w / w asphaltene. The final compositions of the various dope solutions are shown in Table 1.Table 1: Dope solution compositions (Asphaltene and PAN content is a percentage of total carbon content)Weight percentageComponent DS1 DS2 DS3 DS4 DS5 DS6 DS7 DS8 Carbon contentAsphaltene 2 4 6 8 2 4 6 8 PAN 18 16 14 12 18 16 14 12 Toluene 10 20 30 40Pyridine 10 20 30 40DMSO 70 60 50 40 70 60 50 40

[0196] The dope preparation process was observed to be important to the wet-spinning of S2 samples. The formation of homogenous dope without any air bubbles can be used to avoid developing any physical impurities in the wet-spun precursor fibre.Wet-spinning of 1 of 100 filaments

[0197] The overall spinning process can be categorized in number of steps as shown in Figure 4. Wet-spinning process involves number of parameters including dope temperature, coagulation bath composition and its temperature, feed rate, washing bath and hot water bath temperature, spin finish composition, extent of stretch during drying, and winding speed. DS1-DS3 were used for wet-spinning tests along with a control of PAN

[0198] Wet-spinning parameters used for preliminary wet-spinning tests are shown in Table 2.Table 2: Wet spinning parametersParameter Value (range)Dope temperature 50-60°CCoagulation bath temperature RT-60°CWashing bath temperature RTDrawing bath 1 temperature 80-95°CDrawing bath 2 temperature 80-95°CDrawing bath 1 draw ratio 2-5Drawing bath 2 draw ratio 5-6Godet roller 1 temperature 120-140°CGodet roller 2 Temperature 120-140°CGodet roller draw ratio 6-8Winding speed 8-10

[0199] The dope solutions prepared with 10, 20 and 30 wt% was found to be easily spinnable and the entire dope was consumed without any fibre breakage or interruption in the spinning process. During the spinning process approximately 200 to 250m of fibres were obtained (Figure 5).

[0200] Preliminary wet-spinning tests for S4 showed it was difficult to spin since the viscosity of this dope solution was lower and fibres were not able to take the stretch. Without being bound by theory, the inventors opine that the low viscosity of the S4 was associated with the low quantity of PAN and DMSO. In the dope preparation process, the reduction of DMSO causes significant loss of viscosity of the solution and subsequent precursor fibre become so brittle that these do are not able to stretch during the spinning process.

[0201] The performance of the developed precursor fibres was evaluated through the single fibre filament tensile testing (Favimat) and compared the control. Results are shown in Table 3.Table 3: Performance of the precursor fibresElongation Diameter Tensile strength Tensile modulus Sample(%) (pm) (MPa) (GPa) Control PAN 12.5 12.01 550 11.64 10% S2 with pyridine 17.1 20.45 80 4.6 20% S2 with pyridine 12.65 23.48 110 5.6330% S2 with pyridine 4.17 28.6 60 3.71

[0202] The optimization of spinning parameters is also crucial to develop aligned crystallographic structure along the fibre length because fibre structure-property relationship of carbon fibre strongly depends on well aligned crystallographic structure of precursor fibre. The fibre crystallographic alignment is generally obtained by stretching of the fibre during spinning process. Optimised wet-spinning parameters used for wet-spinning tests are shown in Table 4.Table 4: Wet spinning parametersParameter Value (range)Dope temperature 50-60°CCoagulation bath temperature RT-60°CWashing bath temperature 50°CDrawing bath 1 temperature 80-95°CDrawing bath 2 temperature 90-100°CDrawing bath 1 draw ratio 5-6.5Drawing bath 2 draw ratio 6.5-8Godet roller 1 temperature 130-140°CGodet roller 2 Temperature 140-150°CGodet roller draw ratio 8-15Winding speed 15-20

[0203] The purpose of this trial was to reduce the fibre diameter and enhance the crystallographic orientation in the fibre by virtue of high stretching. As shown in the Figure 6 and Table 5, the higher stretching of the fibre renders improvement in the mechanical properties but reduction in the elongation to break. It also evident from Table 5 that we have even surpassed the modulus of 10 %w / w and 20 %w / w of S2 precursor fibre compared to pristine PAN.Table 5: Performance of the precursor fibresSample Elongation Diameter Tensile strength Tensile modulus (%) (pm) (MPa) (GPa) Control PAN 12.5 12.01 550 11.6410% S2 6.49 9.91 480 13.9820% S2 6.86 12.10 370 13.2430% S2 8.78 12.92 190 7.55Temperature profile for stabilization and carbonization using carbon nexus research line

[0204] Carbon Nexus research line requires minimum of 700 m of 1000 filaments to run one condition of stabilisation and carbonisation. The process for dope preparation for 1000 filament was kept similar to the dope preparation for 100 filaments as described above. Dope solutions prepared with 10 %w / w, 20 %w / w, and 30 %w / w asphaltene as a percentage of carbon source were prepared using pyridine as the asphaltene solvent and DMSO as the PAN solvent.

[0205] Carbon Nexus research line is approximately 60-70m in length having four zones of stabilisation, 3 zones of low-temperature carbonisation (LT furnace) and two zones of high temperature carbonisation (HT furnace). Stabilisation and carbonisation parameters are shown in Table 6.Table 6: Stabilisation and carbonisation parameters10 20 30 ResidenceTemperature %w / w %w / w %w / w Stage Zone# Time(°C) Tension(min)(cN)Zone 1 230 22.5 152 120 102 128 Zone 2 240 22.5 152 156 120 130 StabilisationZone 3 250 22.5 225 161 128 210 Zone 4 260 22.5 233 165 134 212 LT Z1 400 5.625LT Z3 800 5.625 132 126 121 141 Carbonisation LT Z2 600 5.625HT Z1 1300 5.625307 272 281 331HT Z2 1600 5.625

[0206] Single fibre filament test (Favimat) is one the primary method to evaluate the performance of the developed CF. The properties evaluated by Favimat demonstrated low mechanical performance for both 20 and 30 wt% of the AOA-CF as shown in Figure 6. The targeted mechanical properties for AOA-CF were projected to be 1.70 GPa tensile strength and 170 GPa of tensile modulus (i.e. DOE target performance). Being a first ever trial of AOA for CF, we were cautious during the entire trial and envisaged to preliminary parameters which converts AOA precursor into CF.

[0207] RAMAN spectroscopy to identify the G (graphitic) and D (disordered induced) bands in carbon fibre. When, ladder structure of the PAN fibre coalesces to form the graphitic structure along the axis of carbon fibre, it generates some form of disordered turbostratic structure (sp3 carbon atom) instead of fully ordered graphitic structure (sp2 carbon atom). In this context, the disordered turbostratic of the carbon is associated to the D- band while graphitic carbon belongs to G-band and its ratio is manifested as qualitative parameter for carbon fibre. In general, the relative intensity of D- band (ID) and G-band (IG) are widely influenced by the number of factors including size of the sp2 graphitic structure, ratio of sp2 / sp3 hybridization ratio, disordered bond etc. Figure 7 shows the RAMAN spectrum of developed AOA carbon fibres. The RAMAN results have revealed that carbon fibre with better mechanical properties have lower ID / IG ratio i.e., the carbon fibre which exhibit the higher mechanical properties possess lower disordered structure along the axis of the fibre.

[0208] The turbostratic structure of carbon fibre is formed due to the series of phenomenon including dehydrogenation, decomposition, rearrangement, and growth process. In this entire process, the crystallographic growth happens largely along the length of the carbon fibre. But some level of growth also occurs in transverse direction called as apparent crystalline thickness (Lc). The analysis of crystallographic growth in c-direction is primarily investigated by using XRD. Apart from Lc, XRD analysis also renders interlayer spacing (d), calculated from Brag’s law. The X-ray analysis of the AOA-CF has been represented in Figure 8. The X-ray analysis of the carbon fibre has revealed the d002 plane at 25.32 for 20 wt% of AOA-CF and 25.12 for 30 wt% AOA-CF. As shown in Table 11, Brag’s angle and Lc was found to be reduced for 30 wt% AOA-CF when compared to 20 wt% AOA-CF, which indicates lower weight fraction of AOA-CF have better crystalline growth compared to high weight fraction fibre. It is important to note here that the value obtained for doo2 and Lcis comparable to commercially available T300 CF.Table 7: XRD analysis of carbon fibreCarbon fibre doo2 (nm) Lc(nm)T300 0.3579 1.67920 wt% AOA-CF 0.3515 1.67930 wt% AOA-CF 0.3535 1.583

[0209] The above results demonstrate the production of carbon fibre including up to 30 %w / w of asphaltene substituted for PAN as the carbon source. The results demonstrate that asphaltene can be potentially used as a low cost and sustainable substitute for PAN in the production of carbon fibre. Further, carbon fibre formed using asphaltene as at least a portion of the carbon source in the dope solution is a viable source for producing carbon fibre with the high-performance parameters.

Claims

CLAIMS1. A dope solution for wet-spinning of precursors to carbon fibres, the dope solution comprising:a carbon source comprising:asphaltene, andpolyacrylonitrile;an asphaltene solvent; anda polyacrylonitrile solvent,wherein:the asphaltene solvent and the polyacrylonitrile solvent are miscible.

2. The dope solution of claim 1, wherein the weight ratio of the asphaltene to the asphaltene solvent in the dope solution is in the range of between about 1 : 1 to about 1 :20, between about 1 :2 to about 1 : 10, or about 1:5.

3. The dope solution of claim 1 or claim 2, wherein the asphaltene content in the carbon source (% w / w based on the total weight of the carbon source) is between about 1 to about 40, or between about 5 to about 35.

4. The dope solution according to any one of claims 1 to 3, wherein the polyacrylonitrile content in the carbon source (% w / w based on the total weight of the carbon source) is between about 60 to about 99, or between about 65 to about 95.

5. The dope solution according to any one of claims 1 to 4, wherein the carbon source content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 40, or between about 15 to about 25.

6. The dope solution according to any one of claims 1 to 5, wherein the asphaltene solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 50, or between about 5 to about 30.

7. The dope solution according to any one of claims 1 to 6, wherein the polyacrylonitrile solvent content in the dope solution (% w / w based on the total weight of the dope solution) is between about 1 to about 60, or between about 5 to about 50.

8. The dope solution according to any one of claims 1 to 7, wherein the asphaltene solvent is selected from benzene, toluene, xylene (o-, m-, p-isomers), ethylbenzene, cumene (isopropylbenzene), styrene, mesitylene (1,3,5-trimethylbenzene), pseudocumene (1,2,4-trimethylbenzene), durene (1,2,4,5-tetramethylbenzene), naphthalene, tetralin (tetrahydronaphthalene), decalin (decahydronaphthalene), phenol, chlorobenzene, bromobenzene, nitrobenzene, anisole (methoxybenzene), cresol (m-, o-, p- isomers), pyridine, quinoline, indene, biphenyl, diphenylmethane, triphenylmethane, benzyl alcohol, benzyl benzoate, diphenyl ether, phthalates (optionally, dibutyl phthalate, dimethyl phthalate), acetone, acetonitrile, dimethyl sulfoxide (DMSO), dimethylformamide (DMF), tetrahydrofuran (THF), N-methyl-2-pyrrolidone (NMP), ethyl acetate, propylene carbonate, 1,3-dioxolane, di chloromethane (DCM), chloroform, tetrachloroethylene, trichloroethylene, 1,2-di chloroethane, chlorobenzene, dimethylacetamide (DMAc), hexamethylphosphoramide (HMPA), sulfolane, y-butyrolactone (GBL), 1 ,2-dimethoxy ethane (DME), N,N-di ethylformamide (DEF), formamide, carbon tetrachloride, 1,1,1 -tri chloroethane, trichlorofluoromethane (CFC-11), dichlorodifluoromethane (CFC-12), 1,2-dibromoethane, bromotrifluoromethane, and combinations thereof9. The dope solution according to any one of claims 1 to 8, wherein the asphaltene solvent is selected from toluene, pyridine, chloroform, tetrahydrofuran, and combinations thereof.

10. The dope solution according to any one of claims 1 to 9, wherein the polyacrylonitrile solvent is selected from dimethyl sulfoxide (DMSO), dimethylformamide (DMF) and dimethylacetamide (DMAc), ethylene carbonate, propylene carbonate, dimethyl sulfone (DMSO2), and combinations thereof11. The dope solution according to any one of claims 1 to 10, wherein the polyacrylonitrile solvent is selected from dimethyl sulfoxide (DMSO), dimethyl sulfone (DMSO2), dimethylformamide (DMF) and dimethylacetamide (DMAc), ethylene carbonate, propylene carbonate, and combinations thereof.

12. The dope solution according to any one of claims 1 to 11, wherein the water content (% w / w) in the dope solution is less than about 1.

13. The dope solution according to any one of claims 1 to 12, wherein the dope solution is substantially free of water.

14. The dope solution according to any one of claims 1 to 12, wherein the molecular weight (g / mol) of polyacrylonitrile is between about 70000 to about 500000, or between about 150000 to about 200000.

14. The dope solution according to any one of claims 1 to 12, wherein the viscosity (Pa.s) of the dope solution is between about 10 to about 600, or between 150 to about 300.

15. A process of forming a dope solution, the process comprising:combining asphaltene and an asphaltene solvent to form an asphaltene mixture; optionally, agitating the asphaltene mixture;introducing a polyacrylonitrile solvent to the asphaltene mixture to form a dual solvent mixture;optionally, agitating the dual solvent mixture; andintroducing polyacrylonitrile to the dual solvent mixture to form the dope solution.

16. The process of claim 15, wherein the agitating the asphaltene mixture is by sonication.

17. The process of claim 15 or claim 16, wherein the agitating the dual solvent mixture is by sonication.

18. The process according to any one of claims 15 to 17, wherein the agitating the asphaltene mixture is performed for a period of time (hours) of between about 0.1 to about 5.

19. The process according to any one of claims 15 to 18, wherein the agitating the dual solvent mixture is performed for a period of time (hours) of between about 0.1 to about 5.

20. The process according to any one of claims 15 to 19, introducing the polyacrylonitrile solvent to the asphaltene mixture comprises stirring the asphaltene mixture.

21. The process according to any one of claims 15 to 20, introducing the polyacrylonitrile to the dual solvent mixture comprises stirring the dual solvent mixture.

22. The process according to any one of claims 15 to 21, wherein the dope solution is a dope solution according to any one of claims 1 to 14.

23. A process for forming a carbon fibre, the process comprising:obtaining a dope solution of any one of claims 1 to 14;wet-spinning the dope solution to form a precursor fibre;stabilising the precursor fibre to form a stabilised precursor fibre; and carbonising the stabilised precursor fibre to form the carbon fibre, wherein the wet-spinning comprises:extruding the dope solution through a spinneret at least partially immersed in a coagulation bath to form the precursor fibre; andremoving the precursor fibre from the coagulation bath.

24. The process of claim 23, wherein the process further comprises drying the asphaltene prior to forming the dope solution.

25. The process of claim 23 or claim 24, wherein the wet-spinning the dope solution is performed at a temperature (°C) of between about 40 to about 80, or between about 55 to about 65.

26. The process according to any one of claims 23 to 25, wherein the process further comprise filtering the dope solution prior to the wet-spinning the dope solution.

27. The process according to any one of claims 23 to 26, wherein the process further comprises degassing the dope solution prior to the wet-spinning the dope solution.

28. The process of any one of claims 23 to 27, wherein the coagulation bath is at a temperature (°C) of between about 40 to about 80, or between about 55 to about 65.

29. The process of any one of claims 23 to 28, wherein the extruding of the dope solution though the spinneret is performed at a speed (m / min) of between about 0.1 to 1, or between about 0.25 to 0.75.

30. The process according to any one of claims 23 to 29, wherein the removing the precursor fibre from the coagulation bath is performed at a speed (m / min) of between about 0.5 to 2.

31. The process according to any one of claims 23 to 30, wherein the wet-spinning further comprises stretching the precursor fibre prior to stabilising the precursor fibre.

32. The process according to any one of claims 23 to 31, wherein the wet-spinning further comprises washing the precursor fibre prior to stabilising the precursor fibre.

33. The process according to any one of claims 23 to 32, wherein the wet-spinning further comprises spin-finishing the precursor fibre prior to stabilising the precursor fibre, wherein the spin-finishing comprises:contacting the precursor fibre with a spin-finish solution.

34. The process according to any one of claims 23 to 33, wherein the wet-spinning further comprises drying the precursor fibre prior to stabilising the precursor fibre.

35. The process according to any one of claims 23 to 34, wherein the stabilising the precursor fibre is performed in two or more stabilising stages.

36. The process according to any one of claims 23 to 35, wherein the stabilising the precursor fibre is performed at a temperature (°C) of between about 200 to about 300.

37. The process according to any one of claims 23 to 36, wherein the stabilising the precursor fibre is performed for a period of time (mins) of between about 20 to about 120.

38. The process according to any one of claims 23 to 37, wherein the carbonising the stabilised precursor fibre is performed at a temperature (°C) of between about 300 to about 1800.

39. The process according to any one of claims 23 to 38, wherein the carbonising the stabilised precursor fibre is performed for a period of time (mins) of between about 5 to about 60.

40. The process according to any one of claims 23 to 39, wherein the carbonising the stabilised precursor fibre comprises a low temperature carbonising and a high temperature carbonising.

41. The process of claim 40, wherein the low temperature carbonising is performed at a temperature (°C) of between about 300 to about 900.

42. The process of claim 40 or claim 41, wherein the high temperature carbonising is performed at a temperature (°C) of between about 900 to about 1800.

43. The process according to any one of claims 40 to 42, wherein the low temperature carbonising performed in two or more low temperature carbonising stages.

44. The process according to any one of claims 40 to 43, wherein the high temperature carbonising performed in two or more high temperature carbonising stages.

45. A dope solution obtained from the process of any one of claims 15 to 22.

46. A precursor fibre obtained from the process of any one of claims 23 to 44, wherein the precursor fibre has one or more of:a diameter (pm) of between about 1 to about 35;an elongation (%) of at least about 5;a tensile strength (MPA) of at least about 50; anda tensile modulus (GPa) of at least about 3.5.

47. A carbon fibre obtained from the process of any one of claims 23 to 44, wherein the carbon material has one or more of:a diameter (pm) of between about 1 to about 35;a tensile strength (GPa) of at least about 1;a tensile modulus (GPa) of at least about 150;a doo2 (nm) of between about 0.35 to about 0.36;a Lc (nm) of between about 1.5 to about 1.7; andan ID / IG ratio of between about 0.85 to about 0.9.

Images