Sustainable Fabrication of High‐Strength Polyethylene Ultrafine Fiber Membranes via Gel Melt Differential Electrospinning

High‐strength polyethylene membranes are typically fabricated via flash spinning. However, this method involves substantial use of trichlorofluoromethane as a solvent, posing significant safety hazards and high energy consumption. In this study, LLDPE gel melt differential electrospinning was successfully developed, enabling the fabrication of polyethylene ultrafine fiber membranes without the use of hazardous solvents. The swelling and dissolution behavior of a low‐molecular‐weight, highly branched LLDPE/white oil system was systematically investigated at 220°C. Under shear conditions, LLDPE particles fully disintegrated, facilitating molecular chain disentanglement and the formation of a homogeneous, transparent gel. Mechanical and structural characterization of membranes prepared at varying gel concentrations revealed an optimal composition of 36 wt% LLDPE, which exhibited as‐spun properties including a tensile strength of 24 MPa, an elongation at break of approximately 610%, a network chain density of 6.617 mol/m 3 , and a crystallinity of 47%. Subsequent cold drawing increased the tensile strength to 50 MPa (with elongation retained at 90%), while slightly reducing crystallinity to 46%. Notably, this approach eliminates the need for toxic solvents without compromising mechanical performance. This work presents a sustainable and efficient strategy for producing high‐strength ultrafine polyethylene fiber membranes, offering a transformative alternative to conventional technologies and advancing the mechanistic understanding of gel spinning in the development of high‐performance polymeric materials.