Tough and recyclable elastomers/carbon fiber composites with excellent cutting and puncture resistance

Carbon fiber-reinforced polymers (CFRPs) have shown significant potential for application in personal protective equipment (PPE). However, conventional CFRPs suffer from critical drawbacks including catastrophic brittle fracture, insufficient toughness, and poor recyclability. In this study, a reversibly crosslinked poly(thioctic acid) elastomer (denoted as LATZ) was successfully synthesized and combined with carbon fiber fabric to fabricate a CF/LATZ composite. The resulting material exhibits outstanding comprehensive mechanical performance: the single-layer CF/LAT 0.75 Z composite (T300, 300 gsm fabric, ∼0.55 mm thick) achieves a tensile strength of 429.6 MPa; the three-layer CF M /LAT 0.75 Z composite (T700, 400 gsm fabric, ∼1.31 mm thick) reaches a puncture force of 46.2 N; and the CF/LAT 0.5 Z composite (T300 fabric, 300 gsm) delivers an exceptionally high tear fracture energy of 1465.4 kJ m −2 . Consequently, the CF/LAT 0.75 Z composite displays remarkable resistance to both cutting and puncture, primarily attributed to the excellent flexibility and favorable interfacial compatibility of the LATZ polymer, which enables efficient energy dissipation under loading. Furthermore, the composite exhibits outstanding protective performance against high-speed arrow impact, demonstrating promising potential for use in PPE such as protective clothing and shields, and possibly in impact-resistant gear after further development. Benefiting from the dynamic reversible bonds and weak interactions within the polymer network, the CF/LAT 0.75 Z composite also possesses excellent closed-loop recyclability. This study provides a novel strategy for the design and sustainable recycling of high-performance, carbon fiber composites.