Nonwovens made of recycled carbon fibres as basic material ... · Carbon Fibre Nonwoven ...

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7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 [email protected]

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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7th International CFK-VALLEY STADE CONVENTION „Latest Innovations in CFPR Technology” 11-12 June 2013 [email protected] 2

Agenda

Carbon fibres - applications and necessity of

recycling

Results of different research challenges

Available systems engineering at STFI

Future prospects

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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)

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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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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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Available systems engineering at STFI

Tearing

Cutting

Lapping

Sliver

processing Carding

Take-up

Stitch-

bonding

Needle-

punching

Thermo-

fixation

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Carbon fibre nonwovens lab

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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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Different fabrics: Needle-punched nonwoven

Fibre web/nonwoven:

100 % carbon fibre

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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)

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Shaping/drapability via static puncture test

Verformung

Ve

rfo

rmu

ng

[m

m]

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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

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Fibre volume content

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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

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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

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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

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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

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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

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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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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: [email protected]

Fax: +49 371 5274-153 Internet: www.stfi.de

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Nonwovens made of recycled carbon fibres as basic material ... · Carbon Fibre Nonwoven ...

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