JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 50

recycling

Nonwovens for composites - recycling
carbon waste in the form of long fibres
Since 2005, the Saxon Textile Research Institute
(STFI) has been working on recycling carbon fibre
waste and on the production of semi-finished textile products using recycled carbon fibres.

By
Dipl.-ing. (BA) mArcel hofmAnn,
Dipl.-ing. BernD gulich,
reSeArch ASSociATeS nonwovenS/recycling DepArTmenT
SAxon TexTile reSeArch inSTiTuTe

be used in application areas where prohibitive costs previously
made their use difficult or impossible.

First steps with primary fibres
The aim of the project's work was to investigate the processability of long carbon fibres. A special carding device, a
modified cross lapper and a stitch-bonding machine (type
Maliwatt) were used to this end. In a first step, the researchers
tested whether long staple primary carbon fibres can generally
be formed into a mat by mechanical carding. Due to smaller
amounts of recycled fibres available at the beginning of the
project in 2005, the fibre material was produced by cutting raw
material in the form of rovings with a chopper. The material
was characterized by a high carbon content, with lengths of 50
mm and 100 mm. For the first time, it was possible to create
a fibre web of primary carbon fibres using a carding process
(Figure 1). Based on the results from these tests, the research
goal that emerged was to process recycled carbon fibres appropriately.

C

arbon fibre waste is a comparatively young and undeveloped type of waste that will extensively grow over the
next decades. In the future, the application of carbon
fibre reinforced plastics (CFRP) will increase in the construction of vehicles, in particular in the e-mobility sector, based on
their extreme lightweight construction potential in comparison to materials traditionally used like steel and aluminium.
Analysts consider the CFRP market to be a solid market with
great growth potential. Its annual growth is estimated at a
minimum of 10% and the global demand is expected to reach
89,000 tons in 2020 [1].

With the application of CFRP in different industrial sectors,
the amount of fibre material waste available will strongly
increase in the future as well. This fibre waste comes from
cutting scrap - so called "production waste" - as well as "reclaimed fibres". Therefore, it is a necessity to bring these carbon fibres made from energy-intensive production methods
back into the cycle of material use.
Making recycled carbon fibres of sufficient length available
requires a completely new approach - it is a challenge and a
chance for the nonwoven industry to join the CFRP boom.
Carbon fibre-based nonwovens, fibre tapes and yarns can thus

Fig. 1: Recycled carbon fibres after modified tearing process

Waste as a favoured raw material
Based on the experience gained, the existing line was successfully used to reproduce the results of the first stage with
carbon fibres sourced from recycled composite parts after pyrolysis (end-of-life waste). Carbon fibres with a defined length
of 30 to 100 mm represent the raw material of "reclaimed
fibres".
During the past years, the main focus of detailed project works
was to develop a process to recycle dry carbon waste at the
industrial scale. STFI succeeded in solving this task with a
modified tearing process using defined material control and

50 jec composites magazine / No98 July - August 2015



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015

Cover
Edito
Point of view : business development
Contents
COMPANY & BUSINESS
In brief
Cluster
SME
Agenda of Events
APPLICATIONS
Sports & leisure
Safety
Sports & leisure
MARKET
Resins
FEATURE AUTOMOTIVE
Materials
Binder
Additive
CFRP
Epoxy
Hybrid polymer
QSP
CRTP
Rear axles
Tanks
Engines
RESEARCH & DEVELOPMENT
Fractography
Recycling
TECHNOLOGY & INNOVATIONS
Ancillary product
Vision system
Nano
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Cover
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 2
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Edito
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Point of view : business development
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 5
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Contents
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 7
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - In brief
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Cluster
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - SME
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 11
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 12
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 13
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 15
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Safety
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ad1
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ad2
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 19
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Resins
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 21
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 22
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Materials
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 24
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Binder
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Additive
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 27
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 28
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 29
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - CFRP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 31
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Epoxy
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 33
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Hybrid polymer
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 35
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - QSP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 37
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 38
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - CRTP
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 40
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 41
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Rear axles
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Tanks
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Engines
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 45
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Fractography
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 47
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 48
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 49
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Recycling
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 51
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Ancillary product
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 53
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Vision system
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 55
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Nano
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - Index
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - In the world
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 59
JEC COMPOSITES MAGAZINE - Issue #98 - July/August 2015 - 60
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