GB2590354A - Recyclable carbon-fibre-reinforced composites and processes for forming recyclable carbon-fibre-reinforced composites - Google Patents

Recyclable carbon-fibre-reinforced composites and processes for forming recyclable carbon-fibre-reinforced composites Download PDF

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Publication number
GB2590354A
GB2590354A GB1917220.4A GB201917220A GB2590354A GB 2590354 A GB2590354 A GB 2590354A GB 201917220 A GB201917220 A GB 201917220A GB 2590354 A GB2590354 A GB 2590354A
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carbon
fibre
recyclable
reinforced composite
forming
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GB201917220D0 (en
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Mcquilliam John
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PRODRIVE COMPOSITES Ltd
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PRODRIVE COMPOSITES Ltd
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Priority to GB1917220.4A priority Critical patent/GB2590354A/en
Publication of GB201917220D0 publication Critical patent/GB201917220D0/en
Priority to PCT/GB2020/052999 priority patent/WO2021105670A2/en
Priority to EP20819834.1A priority patent/EP4065633A2/en
Publication of GB2590354A publication Critical patent/GB2590354A/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
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    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
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    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation
    • C08J11/12—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by dry-heat treatment only
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
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    • C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
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    • C08K7/04—Fibres or whiskers inorganic
    • C—CHEMISTRY; METALLURGY
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    • C08K7/00—Use of ingredients characterised by shape
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    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/02—Homopolymers or copolymers of acids; Metal or ammonium salts thereof
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    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
    • C08L33/08—Homopolymers or copolymers of acrylic acid esters
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    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
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    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
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Abstract

Processes for forming recyclable carbon-fibre-reinforced composites comprise the following steps. Provide a reinforcement structure 52 formed from a plurality of carbon fibres, the carbon fibres being treated carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment. Then, infiltrate the reinforcement structure with a liquid thermoplastic precursor 54, this is preferably monomers. Then, polymerise the liquid thermoplastic precursor 56, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite. In a preferred embodiment, the thermoplastic polymer is acrylic based. Recyclable carbon-fibre reinforced composites are made using these processes. Preferably the treatment which induces roughness on the carbon fibres is pyrolysis. In some embodiments, the carbon fibres are supplied as a multi-directional mat. Methods for recycling carbon fibre composites are also disclosed.

Description

RECYCLABLE CARBON-FIBRE-REINFORCED COMPOSITES AND PROCESSES FOR FORMING RECYCLABLE CARBON-FIBRE-REINFORCED COMPOSITES
FIELD OF THE INVENTION
The invention relates to the field of recyclable carbon-fibre reinforced composites and in particular to processes for forming recyclable carbon-fibre reinforced composites and components comprising such composites.
BACKGROUND TO THE INVENTION
Carbon-fibre-reinforced polymer-matrix composites may be commonly referred to as carbon fibre reinforced polymers (CFRPs) or simply as carbon fibre composites. Such composites have an established usage in high-value low-volume engineering applications, for example as rotors for helicopters and turbines, as aircraft panels, structures and panels in racing cars, and as components of high performance sporting equipment. The use of CFRPs is increasing, and as components formed from the composites reach the end of their life, the question of recycling or disposal becomes prevalent.
In order to conserve resources and reduce landfill disposal it is desirable that carbon-fibre-reinforced polymer-matrix composites are recycled. However, the polymer matrix in the majority of such composites is formed from a thermosetting polymer, and reclamation of the polymer is prevented by the crosslinks within the polymer itself.
Thermoplastics can be used as the matrix of a carbon-fibre-reinforced polymer-matrix composite. A thermoplastic matrix composite is typically formed by combining a molten thermoplastic resin with a reinforcement. A molten thermoplastic resin is highly viscous, however, and it is difficult to form a bond between reinforcement and the matrix. Orientation of fibre in reinforcement structure, for example, is also difficult to maintain in a finished composite due to the viscosity of a thermoplastic melt.
SUMMARY OF THE INVENTION
The invention may provide a process for forming a recyclable carbon-fibre-reinforced composite or a component formed from a recyclable carbon-fibre-reinforced composite as defined in any of the appended claims.
Aspects of the present invention are defined by the independent claims below to which reference should now be made. Optional features are defined by the dependent claims.
Arrangements are described in more detail below and take the form of processes for forming recyclable carbon-fibre-reinforced composites that comprise the following steps.
Provide a reinforcement structure formed from a plurality of carbon fibres, the carbon fibres being treated carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment. Then, infiltrate the reinforcement structure with a liquid thermoplastic precursor. Then, polymerise the liquid thermoplastic precursor, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite. Recyclable carbon-fibre-reinforced composites are made using these processes.
A process for forming a recyclable carbon-fibre-reinforced composite in which the process may comprise the steps of: providing a reinforcement structure formed from a plurality of carbon fibres, the carbon fibres being treated carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment; infiltrating the reinforcement structure with a liquid thermoplastic precursor, and polymerising the liquid thermoplastic precursor, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite.
Virgin carbon fibres have a smooth outer surface. By providing a treatment that results in an increased mechanical roughness of the outer surface, an increased mechanical interaction with the matrix phase of the composite may result in an increased strength of the finished composite.
A liquid thermoplastic precursor may have a viscosity that is comparable with water. Thus, the liquid thermoplastic precursor may be able to infiltrate surface roughness of the carbon fibres more effectively or more completely than would a molten thermoplastic, which would be of significantly increased viscosity.
The viscosity of the thermoplastic precursor may be a dynamic viscosity of 50mPas to 1000 mPas.
Infiltration of a molten thermoplastic into the reinforcement structure may require both high temperature and high pressure. This may significantly increase the complexity and cost of equipment required to produce such composites. By infiltrating the reinforcement structure with a liquid thermoplastic precursor, which preferably has a room temperature viscosity that is comparable to the room temperature viscosity of water (a dynamic viscosity of about 1mPas), the need for such expensive and complicated equipment may be negated, lowering the overall costs of the resulting composite.
A process for forming a recyclable carbon-fibre-reinforced composite may comprise the steps of: providing a reinforcement structure formed from a plurality of carbon fibres, the carbon fibres being reclaimed carbon fibres obtained as a result of a reclamation process on a pre-existing carbon-fibre-reinforced composite, infiltrating the reinforcement structure with a liquid thermoplastic precursor, and polymerising the liquid thermoplastic precursor, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite.
The outer surface of the carbon fibres may be roughened as a result of material being removed from the outer surface of the carbon fibres by the treatment. Alternatively, or in combination, the outer surface of the carbon fibres may be enhanced for bonding as a result of material being added to the outer surface of the carbon fibres by the treatment.
This effectively creates a roughened surface.
The treatment may comprise one or more steps, at least one of the steps involving a mechanical process, a chemical process, or a pyrolytic process.
The plurality of carbon fibres may comprise reclaimed carbon fibres reclaimed from a pre-existing carbon-fibre-reinforced polymer-matrix composite. The treatment may include at least a step of reclaiming the carbon fibres from a pre-existing carbon-fibre-reinforced polymer-matrix composite. The plurality of carbon fibres may comprise mostly or more than 50% reclaimed carbon fibres (by weight) reclaimed from a pre-existing carbon-fibrereinforced polymer-matrix composite. As mentioned above, reclamation of the carbon fibres may not be fully complete or partially complete. The reclaimed carbon fibres may have a surface comprising a plurality of projections formed by remnants of the polymer-matrix of the pre-existing carbon-fibre-reinforced polymer-matrix composite. The plurality of projections may contribute to the surface roughness. The reclaimed carbon fibres may have a surface comprising a plurality of gouges, grooves, or cavities formed by the treatment. The plurality of gouges, grooves, or cavities may contribute to the surface roughness. In this way, the reclaimed or partially reclaimed carbon fibres have a good surface for bonding with a new thermoplastic matrix.
The reinforcement structure may be in the form of a sheet comprising the plurality of carbon fibres. The plurality of carbon fibres may have an average length of between 10 mm and 150 mm. The reinforcement structure may be in the form of a chopped fibre sheet.
The plurality of carbon fibres may be arranged in multiple directions in the x/y plane of the sheet. The sheet may be a multi-directional-fibre sheet. The plurality of carbon fibres may be arranged randomly in the x/y plane of the sheet.
The liquid thermoplastic precursor may comprise polymerisable monomers. The liquid thermoplastic precursor may comprises acrylic monomers. The acrylic monomers may comprise acrylates and/or methacrylates, for example, salts and/or esters of methacrylic acid. The resulting thermoplastic matrix encapsulating the reinforcement structure may be an acrylic matrix.
The process may comprise the step of locating the reinforcement structure within a skin comprising a polymeric material. Infiltrating the reinforcement structure with the liquid thermoplastic precursor may be such that the skin is located at an outer surface of the recyclable carbon-fibre-reinforced composite. The skin may be formed from one or more sheets of fibre reinforced polymer matrix composite. The skin may be formed from one or more sheets of carbon-fibre-reinforced polymer matrix composite. The carbon-fibrereinforced polymer matrix composite forming the skin may contain a bi-directional orientation of carbon fibres. The skin may be formed from one or more sheets of recyclable carbon-fibre-reinforced composite made according to the process described above.
It can be difficult to retain the multidirectional fibre orientation with a thermoplastic matrix. This is because of the high viscosity of the thermoplastic melt. In the process described above, the skin helps to retain the orientation of the fibres of the reinforcement structure.
The process for forming a recyclable carbon-fibre-reinforced composite may comprise the further step of shaping and/or machining the recyclable carbon-fibre-reinforced composite into a component. The component may be for a vehicle, for example a car, such as a vehicle or car body panel. The process for forming a recyclable carbon-fibre-reinforced composite may comprise the further step of providing an initial recyclable carbon-fibre-reinforced composite formed by a process as described above, and cutting the initial recyclable carbon-fibre-reinforced composite into a plurality of discrete portions. The plurality of discrete portions may be consolidated to form a subsequent recyclable carbonfibre-reinforced composite.
A process for forming a recyclable carbon-fibre-reinforced composite, the process comprising the steps of: providing a primary component formed from a carbon-fibre-reinforced composite, reclaiming carbon fibres from the primary component by a pyrolysis treatment, forming the reclaimed carbon fibres into a reinforcement structure, infiltrating the reinforcement structure with a liquid thermoplastic precursor, and polymerising the liquid thermoplastic precursor, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form a secondary component formed from a carbon-fibre-reinforced composite.
The process may comprise the further steps of: cutting the secondary component into a plurality of discrete portions, and consolidating the plurality of discrete portions to form a tertiary component formed from a carbon-fibre-reinforced composite.
A process for recycling carbon fibre composites, the process comprising the steps of: reclaiming carbon fibres from a primary carbon fibre reinforced polymer composite component thereby forming reclaimed carbon fibres; forming a secondary carbon fibre reinforced polymer component by combining the reclaimed carbon fibres with a liquid thermoplastic resin, and polymerising the liquid thermoplastic resin to form the secondary carbon fibre reinforced polymer component; forming a feedstock for a tertiary carbon fibre reinforced component by cutting the secondary carbon fibre reinforced composite into a plurality of particles; and forming a tertiary carbon fibre reinforced composite component by consolidating the feedstock.
A component formed from a recyclable carbon-fibre-reinforced composite, the component comprising: a reinforcement structure formed from a plurality of carbon fibres, the carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment, and a thermoplastic matrix.
A component formed from a recyclable carbon-fibre-reinforced composite, the component comprising: a reinforcement structure in the form of a sheet formed from a plurality of carbon fibres, the carbon fibres being between 10 mm and 100 mm in length and multidirectionally oriented in the plane of the sheet, and a thermoplastic matrix.
The plurality of carbon fibres may be randomly oriented in the plane of the sheet.
A component formed from a recyclable carbon-fibre-reinforced composite, the component having an outer layer comprising an outer layer reinforcement structure and an outer layer polymer matrix, and a core comprising a core reinforcement structure and a core polymer matrix, in which the outer layer reinforcement structure is a woven carbon fibre fabric, the core reinforcement structure is a carbon fibre sheet formed of mulfidirectionally oriented carbon fibres having lengths between 10 mm and 100 mm, and the core polymer matrix is a thermoplastic.
The outer layer polymer matrix may be formed from a thermoplastic.
A vehicle body panel, such as a car body panel, may be formed by the processes described above.
SPECIFIC EMBODIMENTS OF THE INVENTION
Specific embodiments of the invention will now be described with reference to the figures, in which: Figure 1 is a flow diagram illustrating a process for forming a sheet forming a reinforcement structure embodying an aspect of the present invention; Figure 2 is an isometric view of a mould tool for use with the process embodying an aspect of the present invention; Figure 3 is a side view of the mould tool of Figure 2 in use; Figure 4 is an isometric view of a component embodying an aspect of the present invention made using the mould tool of Figure 2; Figure 5 is a flow diagram illustrating a process for forming a recyclable carbon-fibrereinforced composite embodying an aspect of the present invention; and Figure 6 is a cross sectional view of a mould tool for use with the process embodying an aspect of the present invention.
An example process for forming a recyclable carbon-fibre-reinforced composite will now be described with reference to Figures 1 to 5.
First, referring to the flow diagram 2 of Figure 1, a plurality of carbon fibres are reclaimed from a pre-existing carbon-fibre-reinforced polymer-matrix composite by using a pyrolysis treatment (Figure 1, step 4). The reclaimed carbon fibres have a surface with a plurality of projections formed by remnants of the polymer-matrix of the pre-existing carbon-fibre-reinforced polymer-matrix composite. In other words, in this example, reclamation of the carbon fibres is not fully complete. The surface of the carbon fibres also comprise a plurality of gouges, grooves, or cavities formed by the treatment. The plurality of projections as well as the gouges, grooves, and cavities contribute to the surface roughness of the carbon fibres. The reclaimed carbon fibres have an average length of between 10 mm and 150 mm, or, optionally, are processed to have an average length of between 10 mm and 150 mm (Figure 1, step 6). The reclaimed carbon fibres are then formed into a sheet forming a reinforcement structure (Figure 1, step 8). In this example, the sheet forming the reinforcement structure also includes virgin or primary carbon fibres that have not been reclaimed. However, in this example, the carbon fibres of the sheet comprise more than 50% by weight reclaimed carbon fibres reclaimed from a pre-existing carbon-fibre-reinforced polymer-matrix. In this example, the plurality of carbon fibres are arranged in multiple, random directions in the x/y plane of the sheet to form a multidirectional-fibre sheet.
Next, a recyclable carbon-fibre-reinforced composite is manufactured from the sheet forming the reinforcement structure in a process. Broadly, in the process described below with reference to Figures 2 to 5, a reinforcement structure formed 10 from a plurality of treated carbon fibres is provided and located or positioned on a clean mould tool 12. As mentioned above, the carbon fibres are previously treated (as described above) to have an outer surface that possesses a mechanical roughness. The reinforcement structure in the mould tool is then infiltrated with a liquid thermoplastic precursor. In other words, the precursor ingresses into the reinforcement structure. The liquid thermoplastic precursor is then polymerised. In this way, the reinforcement structure is encapsulated with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite 14.
In more detail, referring first to Figure 2, the mould tool 12 includes two portions 16, 18.
One of the portions 16 has a first shaped mould portion 20 to, after processing, form one surface of the recyclable carbon-fibre-reinforced composite. The other portion 18 of the mould tool has a second shaped mould portion 22 or may comprise a compliant or flexible membrane to, after processing, form another surface of the recyclable carbon-fibrereinforced composite. In this example, the second shaped mould portion projects outwardly from the surface of one portion 18 of the mould tool and fits within the first shaped mould portion that is recessed within the surface of the other portion 16 of the mould tool. A cavity or geometric form is formed between the first and second shaped mould portions. Each of the two portions of the mould tool includes location features 24, 26 to locate the two portions of the mould tool together. In the example of Figure 2, one of the portions 18 of the mould tool has location features 24 in the form of a plurality of projections in the form of pins that each project outwardly from the surface of the portion of the mould tool. The other portion of the mould tool has location features in the form of a plurality of blind holes complementary to the pins into which the pins are located in use. The mould tool also has a resin entry port 28 for the liquid thermoplastic precursor to enter the mould tool and an air exit port 30 for extracting air from the mould tool. In this example, the resin entry port is located in the first mould portion and the air exit port is located in the second mould portion.
In the example process, described in addition with reference to the flow diagram 50 of Figure 5, the reinforcement structure 10 formed from treated carbon fibre reinforcements is provided by positioning the reinforcement structure onto the first shaped mould portion of the clean mould tool (Figure 5, step 52). As illustrated in Figure 3, the two portions or halves of the mould tool are sealed together by locating the location features 24,26 together. The air exit port 30 is then connected to a vacuum source. The vacuum source extracts air from within the mould cavity.
The thermoplastic precursor resin is then introduced into the mould cavity, formed by the two portions 16, 18 of the mould tool 12, through the resin entry port 28. In other words, the reinforcement structure 10 is infiltrated with the precursor (Figure 5, step 54). Previously, appropriate amounts of constituents are mixed together to create the thermoplastic precursor resin. The thermoplastic precursor resin is a liquid. In this example, the viscosity of the liquid is around that of water. The thermoplastic precursor resin comprises polymerisable monomers, in this example, acrylic monomers. The monomers of the precursor resin readily polymerise to form a thermoplastic. In other words, they form a thermoplastic after a short period of time. The thermoplastic precursor resin is introduced into the mould cavity, through the resin entry port, for example, by siphon, draw down from a hopper or pumped/pressurised injection.
Polymerisation of the thermoplastic precursor resin (Figure 5, step 56) occurs after complete infiltration of the carbon fibre reinforcements. The polymerisation may be enhanced by, for example, increased temperature, such as by heating the mould tool, and/or by increased pressure above the infiltration levels.
The resulting thermoplastic is then left to cure for a period of time forming a thermoplastic matrix encapsulating the reinforcement structure is an acrylic matrix. Once the thermoplastic has cured, the resultant carbon-fibre reinforced composite or part is demoulded. Thus, the reinforcement structure is encapsulated with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite. Finally, the recyclable carbonfibre-reinforced composite is trimmed and machined into a component, in this example, into a component for a vehicle or car in the form of a car body panel.
In this way, a component is formed from a recyclable carbon-fibre-reinforced composite.
The component having a reinforcement structure formed from a plurality of carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment, and a thermoplastic matrix. The reinforcement structure is in the form of a sheet formed from a plurality of carbon fibres. The carbon fibres are between 10 mm and 100 mm in length and multidirectionally, randomly oriented in the plane of the sheet, and a thermoplastic matrix.
Another example is illustrated in Figure 6 and like features have been given like reference numerals to the example described above. In this example, a skin 100 is first located on the surface of one part 16 of the mould tool 12. The skin comprises a polymeric material formed from sheets of fibre reinforced polymer matrix composite, in this example, with a bi-directional orientation of carbon fibres. The sheets of fibre-reinforced composite may be recyclable carbon-fibre-reinforced composite formed using the process described above. Then, a reinforcement structure 10 in the form of a sheet formed from at least some treated carbon fibre reinforcements as described above is located on the skin. The reinforcement structure is then infiltrated with the liquid thermoplastic precursor and the process is as described above. Thus, the skin is located at an outer surface of the recyclable carbonfibre-reinforced composite.
In this way, a component formed is from a recyclable carbon-fibre-reinforced composite. The component has an outer layer comprising an outer layer reinforcement structure and an outer layer polymer matrix, in this example, formed from a thermoplastic, and a core comprising a core reinforcement structure and a core polymer matrix. The outer layer reinforcement structure is a woven carbon fibre fabric. The core reinforcement structure is a carbon fibre sheet formed of multidirectionally oriented carbon fibres having lengths between 10 mm and 100 mm. The core polymer matrix is a thermoplastic.
In another example (not illustrated), a feedstock is formed for a tertiary carbon fibre reinforced component by cutting the secondary carbon fibre reinforced composite into a plurality of particles. A tertiary carbon fibre reinforced composite component is formed by consolidating the feedstock.
Embodiments of the present invention have been described. It will be appreciated that variations and modifications may be made to the described embodiments within the scope of the present invention.

Claims (22)

  1. CLAIMS1. A process for forming a recyclable carbon-fibre-reinforced composite, the process comprising the steps of: providing a reinforcement structure formed from a plurality of carbon fibres, the carbon fibres being treated carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment, infiltrating the reinforcement structure with a liquid thermoplastic precursor, and polymerising the liquid thermoplastic precursor, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form the recyclable carbon-fibre-reinforced composite.
  2. 2. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 1, in which the plurality of carbon fibres comprise reclaimed carbon fibres reclaimed from a pre-existing carbon-fibre-reinforced polymer-matrix composite, and the treatment includes at least a step of reclaiming the carbon fibres from the pre-existing carbon-fibre-reinforced polymer-matrix composite.
  3. 3. A process according to claim 2, wherein the plurality of carbon fibres comprise more than 50% reclaimed carbon fibres reclaimed from a pre-existing carbon-fibre-reinforced polymer-matrix composite.
  4. 4. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 2 or 3 in which reclamation of the carbon fibres in not fully complete and the reclaimed carbon fibres have a surface comprising a plurality of projections formed by remnants of the polymer-matrix of the pre-existing carbon-fibre-reinforced polymer-matrix composite, the plurality of projections contributing to the surface roughness.
  5. 5. A process for forming a recyclable carbon-fibre-reinforced composite according to any of claims 2 to 4 in which the reclaimed carbon fibres have a surface comprising a plurality of gouges, grooves, or cavities formed by the treatment, the plurality of gouges, grooves, or cavities contributing to the surface roughness.
  6. 6. A process for forming a recyclable carbon-fibre-reinforced composite according to any preceding claim, in which the reinforcement structure is in the form of a sheet comprising the plurality of carbon fibres.
  7. 7. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 6, in which the plurality of carbon fibres have an average length of between 10 mm and 150 mm and the reinforcement structure is in the form of a chopped fibre sheet.
  8. 8. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 7 in which the plurality of carbon fibres are arranged in multiple directions in the x/y plane of the sheet, the sheet being a multi-directional-fibre sheet.
  9. 9. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 8 in which the plurality of carbon fibres are arranged randomly in the x/y plane of the sheet.
  10. 10. A process for forming a recyclable carbon-fibre-reinforced composite according to any preceding claim, in which the liquid thermoplastic precursor comprises polymerisable monomers.
  11. 11. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 10, in which the liquid thermoplastic precursor comprises acrylic monomers and the resulting thermoplastic matrix encapsulating the reinforcement structure is an acrylic matrix.
  12. 12. A process for forming a recyclable carbon-fibre-reinforced composite according to any preceding claim, wherein the process comprises the step of locating the reinforcement structure within a skin comprising a polymeric material and infiltrating the reinforcement structure with the liquid thermoplastic precursor such that the skin is located at an outer surface of the recyclable carbon-fibre-reinforced composite.
  13. 13. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 12, in which the skin is formed from one or more sheets of fibre reinforced polymer matrix composite.
  14. 14. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 12 or 13 in which the skin is formed from one or more sheets of carbon-fibre-reinforced polymer matrix composite.
  15. 15. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 14 in which the carbon-fibre-reinforced polymer matrix composite forming the skin contains a bi-directional orientation of carbon fibres.
  16. 16. A process for forming a recyclable carbon-fibre-reinforced composite according to any of claims 12 to 15, in which the skin is formed from one or more sheets of recyclable carbon-fibre-reinforced composite made according to any of claims 1 to 11.
  17. 17. A process for forming a recyclable carbon-fibre-reinforced composite according to any preceding claim comprising the further step of shaping and/or machining the recyclable carbon-fibre-reinforced composite into a component.
  18. 18. A process for forming a recyclable carbon-fibre-reinforced composite according to any preceding claim comprising the further step of providing an initial recyclable carbon-fibrereinforced composite formed by a process as defined in any of claims 1 to 17, cutting the initial recyclable carbon-fibre-reinforced composite into a plurality of discrete portions, and consolidating the plurality of discrete portions to form a subsequent recyclable carbon-fibrereinforced composite.
  19. 19. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 18 in which the initial recyclable carbon-fibre-reinforced composite is a component formed from a recyclable carbon-fibre-reinforced composite as defined in any of claims 1 to 17, and the steps of cutting the initial recyclable carbon-fibre-reinforced composite into a plurality of discrete portions, and consolidating the plurality of discrete portions to form a subsequent recyclable carbon-fibre-reinforced composite, are steps of recycling the first component to form a subsequent component.
  20. 20. A process for forming a recyclable carbon-fibre-reinforced composite, the process comprising the steps of: providing a primary component formed from a carbon-fibre-reinforced composite, reclaiming carbon fibres from the primary component by a pyrolysis treatment, forming the reclaimed carbon fibres into a reinforcement structure, infiltrating the reinforcement structure with a liquid thermoplastic precursor, and polymerising the liquid thermoplastic precursor, thereby encapsulating the reinforcement structure with a thermoplastic matrix to form a secondary component formed from a carbon-fibre-reinforced composite.
  21. 21. A process for forming a recyclable carbon-fibre-reinforced composite according to claim 20, the process comprising the further steps of: cutting the secondary component into a plurality of discrete portions, and consolidating the plurality of discrete portions to form a tertiary component formed from a carbon-fibre-reinforced composite.
  22. 22. A process for recycling carbon fibre composites, the process comprising the steps of: reclaiming carbon fibres from a primary carbon fibre reinforced polymer composite component thereby forming reclaimed carbon fibres; forming a secondary carbon fibre reinforced polymer component by combining the reclaimed carbon fibres with a liquid thermoplastic resin, and polymerising the liquid thermoplastic resin to form the secondary carbon fibre reinforced polymer component; forming a feedstock for a tertiary carbon fibre reinforced component by cutting the secondary carbon fibre reinforced composite into a plurality of particles; and forming a tertiary carbon fibre reinforced composite component by consolidating the feedstock.25. A component formed from a recyclable carbon-fibre-reinforced composite, the component comprising: a reinforcement structure formed from a plurality of carbon fibres, the carbon fibres having an outer surface possessing a mechanical roughness formed as a result of a treatment, and a thermoplastic matrix.26. A component formed from a recyclable carbon-fibre-reinforced composite, the component comprising: a reinforcement structure in the form of a sheet formed from a plurality of carbon fibres, the carbon fibres being between 10 mm and 100 mm in length and multidirectionally oriented in the plane of the sheet, and a thermoplastic matrix.27. A component according to claim 26 in which the plurality of carbon fibres are randomly oriented in the plane of the sheet.28. A component formed from a recyclable carbon-fibre-reinforced composite, the component having an outer layer comprising an outer layer reinforcement structure and an outer layer polymer matrix, and a core comprising a core reinforcement structure and a core polymer matrix, in which the outer layer reinforcement structure is a woven carbon fibre fabric, the core reinforcement structure is a carbon fibre sheet formed of multidirectionally oriented carbon fibres having lengths between 10 mm and 100 mm, and the core polymer matrix is a thermoplastic.29. A component according to claim 28 in which the outer layer polymer matrix is formed from a thermoplastic.30. A vehicle body panel formed by a process according to any of claims 1 to 22.
GB1917220.4A 2019-11-26 2019-11-26 Recyclable carbon-fibre-reinforced composites and processes for forming recyclable carbon-fibre-reinforced composites Pending GB2590354A (en)

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