Post on 02-Apr-2018
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de
Nonwovens made of recycled carbon
fibres as basic material for composites
Dr. Heike Illing-Günther
Dipl.-Ing. (BA) Marcel Hofmann
Dipl.-Ing. Bernd Gulich
Saxon Textile Research Institute,
Chemnitz (Germany)
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Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 2
Agenda
Carbon fibres - applications and necessity of
recycling
Results of different research challenges
Available systems engineering at STFI
Future prospects
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 3
Why Recycling of carbon materials?
• Increasing amount of cutting scrap (production
waste)
• High percentage of non-rectifiable rejects
• Increasing amount of end-of-life-waste in near
future
• Ban on landfill for CFRP materials
• Incineration is problematic
and expensive
• Legislation (e.g. ELV)
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de
Carbon fibre nonwovens
• Investigation of the process ability of long carbon fibres
• Beginning of the first project: The used fibre material was produced
by cutting the raw material in form of rovings with a chopper
• Second stage: Cutting and tearing of production waste/cutting scrap
of resin free CF fabrics
• Third group: Carbon fibres, resulting from recycled composite parts
after pyrolysis or others i.e. solvolysis
• Objectives: Production of fabrics made from carbon fibres on dry
way in a mechanically operated web formation process
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Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de
Manufacture of nonwovens
• Processing of long, but not endless carbon fibres by means of the
carding principle
• In-line entanglement using stitch-bonding technique MALIWATT or
needle-punching
• Before: Preparation of different CF waste /cutting scraps or CF
coming from i.e. pyrolysis using modified cutting and tearing
processes
• Afterwards: Testing of the fabric features by use of different process
lines
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Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 6
Available systems engineering at STFI
Tearing
Cutting
Lapping
Sliver
processing Carding
Take-up
Stitch-
bonding
Needle-
punching
Thermo-
fixation
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 7
Carbon fibre nonwovens lab
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de
MALIWATT - reverse wale
MALIWATT - face wale
Fibre web: 100 % Carbon fibre
Stitching yarn: PES-S texturized; 7.6 tex
Different fabrics: Stitch-bonded nonwoven
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Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 9
Different fabrics: Needle-punched nonwoven
Fibre web/nonwoven:
100 % carbon fibre
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 10
Textile physics
• Realized mass per unit area: 40 - 1500 g/m²
• Realized thickness: 0.8 – 5.7 mm
• Strength / elongation
• Shaping / drapability via static puncture test
(according to DIN EN ISO 12236)
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 11
Shaping/drapability via static puncture test
Verformung
Ve
rfo
rmu
ng
[m
m]
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 12
Force-deformation diagramme
Carbon Fibre Nonwoven –
MALIWATT; cross oriented, Tricot
Mass: 410 g/m²
Stitching yarn: PES texturized;
7.6 tex
Carbon Fibre (Roving)-Woven
Plain weave
Mass: 300 g/m²
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 13
Fibre volume content
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 14
Composite facilities at STFI
FRP – lab (in upgrading)
• Hand lamination
• Press & injection devices
• Testing equipment Tensile strength
Bending strength
Interlaminar shear strength (ILSS)
Compression test…
Moulding press
CF preform
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 15
Results
Web formation by means of carding using 100%
carbon fibres is technically possible
Nonwovens of 100 % CF from i.e. pyrolysis are
possible via needle-punching
Products have a profile of characteristics which
qualifies them for the use in CFRP structures with
medium strength requirements
Ideal applications are in the areas of Integrated functional lightweight construction
Sports / rehabilitation technology
Leisure activities (e.g. camping)
General construction
Architecture
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 16
Possible ideas of use
• Vehicle manufacturing, engineering, sports and
leisure equipment, wind power plants, medical
engineering, architecture
• High wall thicknesses with low weight are
possible
• Extreme high deformation potential during
preform shaping in the mould
Quelle: Opel
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 17
Outlook
• On-going determination of different processing
lines also as hybrid fibre blends for thermo-
bonding and other alternative entanglement
processes
• Characterization of UD oriented nonwovens/
composites (via sliver processing and their
parameters compared to load bearing capacity of
primary fibres/rovings
• Separation of stitching yarns after cutting/tearing
of resin free NCF
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de 18
The publication results from projects which were
supported by the Federal Ministry of Economics and
Technology under Reg.-No. VP 2034018VT0 and VF
120003. We thank the Federal Ministry of Economics
and Technology (BMWi) for the financial promotion.
Acknowledgement
Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de
Sächsisches Textilforschungsinstitut e.V. (STFI) an der Technischen Universität Chemnitz
Saxon Textile Research Institute at Chemnitz University of Technology
International Competence
in Technical Textiles – Nonwovens – Protective Textiles
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Copyright: STFI
7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 Heike.Illing-Guenther@stfi.de
Thank you for your attention!
Sächsisches Textilforschungsinstitut e.V.
Annaberger Straße 240 Managing Director:
09125 Chemnitz Dipl.-Ing.-Ök. Andreas Berthel
Phone: +49 371 5274-0 E-Mail: stfi@stfi.de
Fax: +49 371 5274-153 Internet: www.stfi.de
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