A method of manufacturing a high strength beam using recycled carbon fibre material

Abstract

This invention provides a method for manufacturing high-strength beams using recycled carbon fiber materials, comprising the following steps: S1. Dividing the recycled carbon fiber materials into three categories: flat pieces, round tubes, and irregularly shaped pieces; S2. Cutting the flat pieces into flat materials; S3. Grinding and cleaning the flat materials, dividing them into two groups: one group for the upper cover plate and the other for the lower flat plate; S4. Placing the lower flat plate on an adhesive fixture and applying structural adhesive; S5. Cutting the round tubes and irregularly shaped pieces to a fixed length, grinding to remove burrs, and cleaning to obtain support columns; S6. Vertically placing several support columns and arranging them evenly on the lower flat plate to form an intermediate layer; S7. Applying structural adhesive to the upper cover plate, placing it on the upper surface of the support columns, and pressing it firmly; S8. After the structural adhesive has cured, a semi-finished product is obtained. The fibers of the semi-finished product are wound to form a winding layer. After completion, it is transferred to an oven for curing, demolded, and trimmed to obtain a high-strength beam. This invention manufactures corrosion-resistant high-strength beams by reusing and structurally optimizing recycled carbon fiber materials.

Description

Technical Field

[0001] This invention relates to a method for manufacturing high-strength beams using recycled carbon fiber materials. Background Technology

[0002] With the rapid increase in global carbon fiber usage, the demand for carbon fiber is surging. As the use of carbon fiber composites is experiencing a period of rapid growth, a large amount of waste is generated during the production process, from raw materials to finished products. Statistics show that the average scrap rate of carbon fiber is between 20-30%. Current waste carbon fiber recycling mainly focuses on pyrolysis and chemical recycling methods: pyrolysis uses high temperatures to decompose the resin in the composite material into small organic molecules, thereby recovering the carbon fiber; this is also the earliest commercially viable carbon fiber recycling method. Chemical recycling involves using chemical methods to decompose or degrade the resin matrix of the carbon fiber composite material, achieving carbon fiber recycling.

[0003] These two methods have the following drawbacks: 1) The steps are complex, involving significant investment in related equipment, and the energy consumption during the recycling process is also high. The energy consumption of carbon fiber production itself is also very high. If the energy consumption during the recycling process increases significantly, it will obviously be counterproductive and will inevitably drive up the price of recycled carbon fiber, affecting the rapid development of the carbon fiber recycling industry; 2) The mechanical properties of carbon fibers recycled by the above methods are all reduced to a certain extent, and they all need to be recut and crushed into short fibers for reuse. The performance impact means that they are mainly used in secondary load-bearing structural components; 3) Most existing high-strength carbon fiber beams are made by pultrusion of raw yarn or prepreg laying, which also requires investment in mold costs, resulting in high costs. Therefore, it is necessary to provide a method for manufacturing high-strength beams using recycled carbon fiber materials. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for manufacturing high-strength beams using recycled carbon fiber materials. This method manufactures corrosion-resistant high-strength beams by reusing and structurally optimizing recycled carbon fiber materials.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0006] A method for manufacturing high-strength beams using recycled carbon fiber materials includes the following steps:

[0007] S1. Recycled carbon fiber materials are classified into three categories according to their shape: flat parts, round tube parts, and irregularly shaped parts (flat parts are flat, round tube parts are round, and recycled carbon fiber materials of shapes other than flat or round are classified as irregularly shaped parts).

[0008] S2. Cut the flat part into flat sheet materials;

[0009] S3. After grinding the flat plate material obtained in step S2 in a flat plate grinder, wash it clean, and then divide it into two groups, one group is the upper cover plate and the other group is the lower plate.

[0010] S4. Place the lower plate obtained in step S3 on the bonding fixture and apply structural adhesive to the upper surface of the lower plate.

[0011] S5. Cut round pipes and irregular-shaped parts to a fixed length, grind to remove burrs, and then clean them to obtain support columns;

[0012] S6. Place the support columns obtained in several steps S5 vertically and arrange them evenly on the lower plate after step S4 to form an intermediate layer.

[0013] S7. Apply structural adhesive to the lower surface of the upper cover plate obtained in step S3, then place it on the upper surface of the support column and press it firmly.

[0014] S8. Once the structural adhesive on the lower plate and upper cover plate has cured, a semi-finished product is obtained. The semi-finished product is placed on a winding machine to form a winding layer. After the fiber winding is completed, it is transferred to an oven for curing. After demolding, it is trimmed to obtain a high-strength beam.

[0015] Furthermore, in step S1 of the present invention, the recycled carbon fiber material is one or more of the following: scrapped carbon fiber flat parts for wind turbine blades, scrapped carbon fiber round tube parts for fishing rods, scrapped carbon fiber irregular-shaped parts for automobiles, and other scrapped carbon fiber parts.

[0016] Furthermore, in step S2 of this invention, the width-to-thickness ratio of the flat sheet is 10:1. The length of the flat sheet is not limited and depends on the actual application.

[0017] Furthermore, in step S4 of the present invention, the structural adhesive is a polyurethane structural adhesive or an epoxy structural adhesive, and the coating thickness of the structural adhesive is 0.1 to 0.2 mm.

[0018] Furthermore, in step S5 of the present invention, the width of the support column is 10-50mm. In actual application, the width of the support column is determined according to the thickness of the round tube and the irregular part.

[0019] Furthermore, in step S6 of the present invention, the bonding area between the support column and the lower plate is 10-30% of the area of ​​the lower plate.

[0020] Furthermore, in step S7 of the present invention, the bonding strength between the support column and the upper cover plate / lower plate is 0.1 to 0.3 MPa to prevent the internal structure from slipping during winding.

[0021] Furthermore, in step S8 of this invention, the fiber winding is either wet winding or dry winding, the fiber winding angle is 30–70 degrees, and the thickness of the winding layer is 1–3 mm. The fibers used for fiber winding can be glass fiber, carbon fiber, or other types of fibers.

[0022] Furthermore, in step S8 of the present invention, the curing temperature is 90-120°C and the time is 1-3 hours.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] Recycled carbon fiber materials are generally categorized into flat plates, round tubes, and shaped parts. As is well known, carbon fiber is lightweight and high-strength. This invention involves cutting round tubes and shaped parts to a fixed length to create an intermediate layer that provides vertical support for the carbon fiber beam. Flat plates serve as the top and bottom panels of this intermediate layer, and finally, fiber winding is performed to improve torsional stiffness, resulting in a corrosion-resistant, high-strength beam. On one hand, the recycled carbon fiber material avoids incineration and pyrolysis, reducing carbon dioxide emissions and providing value for secondary use. On the other hand, the carbon fiber beams produced by this method are lightweight, high-strength, and exhibit excellent impact resistance, high compressive and flexural strength, allowing for direct application in some main load-bearing structures or as reinforcing ribs, thus expanding application scenarios and fields. Furthermore, the high-strength carbon fiber beams produced by this invention are comparable in strength to beams directly produced using carbon fiber pultrusion. These beams fully utilize the high strength of carbon fiber in all directions (compressive, flexural, and torsional resistance) and can be used in automotive crash beams. Attached Figure Description

[0025] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, do not constitute an undue limitation of the invention. In the drawings:

[0026] Figure 1 This is a front view schematic diagram of the high-strength beam obtained in Embodiment 1 of the present invention;

[0027] Figure 2 This is a top view schematic diagram of the high-strength beam obtained in Embodiment 1 of the present invention;

[0028] Figure 3 This is a side sectional view of the high-strength beam obtained in Embodiment 1 of the present invention;

[0029] Figure 4 This is a front sectional view of the high-strength beam obtained in Embodiment 1 of the present invention.

[0030] Among them, 1 is the winding layer, 2 is the upper cover plate, 3 is the middle layer, and 4 is the lower plate. Detailed Implementation

[0031] The present invention will now be described in detail with reference to specific embodiments. The illustrative embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention. Example

[0032] To manufacture a high-strength beam, follow these steps:

[0033] S1. Recycled carbon fiber materials are classified into three categories according to their shape: flat parts, round tube parts, and irregularly shaped parts;

[0034] S2. Cut the flat plate (a scrapped carbon fiber flat plate used for wind turbine blades) into two flat plates with a width of 50mm, a length of 1000mm, and a thickness of 5mm. The bending strength of the flat plate can reach more than 1000MPa.

[0035] S3. After grinding the flat plate material obtained in step S2 in a flat plate grinder, wash it clean, and then divide it into an upper cover plate and a lower plate.

[0036] S4. Place the lower plate obtained in step S3 on the bonding fixture, and use an automatic glue applicator to apply polyurethane structural adhesive to the upper surface of the lower plate with a thickness of 0.1 mm.

[0037] S5. Cut the round tube (a scrap carbon fiber round tube for fishing rods) and the irregular part (a scrap carbon fiber irregular part for automobiles) to a fixed length of 20mm. After grinding to remove burrs, clean them to obtain a support column with a width of 20mm.

[0038] S6. The support columns obtained in several steps S5 are placed vertically and evenly arranged on the lower plate after step S4 to form an intermediate layer. The bonding area between the support columns and the lower plate is 10% of the area of ​​the lower plate.

[0039] S7. Apply polyurethane structural adhesive to the lower surface of the upper cover plate obtained in step S3, with a coating thickness of 0.1 mm, and then place it on the upper surface of the support column and press it firmly. The bonding strength between the support column and the upper cover plate / lower plate is 0.2 MPa.

[0040] S8. Once the structural adhesive on the lower plate and upper cover plate has cured, a semi-finished product is obtained. The semi-finished product is placed on a winding machine for dry winding of carbon fiber to form a winding layer. The fiber winding angle is 30 degrees and the thickness of the winding layer is 2mm. After the fiber winding is completed, it is transferred to an oven and cured at 120℃ for 1 hour. After demolding, it is trimmed to obtain a high-strength beam. Example

[0041] To manufacture a high-strength beam, follow these steps:

[0042] S1. Recycled carbon fiber materials are classified into three categories according to their shape: flat parts, round tube parts, and irregularly shaped parts;

[0043] S2. Cut the flat plate (a scrapped carbon fiber flat plate used for wind turbine blades) into two flat plates with a width of 50mm, a length of 1000mm, and a thickness of 5mm.

[0044] S3. After grinding the flat plate material obtained in step S2 in a flat plate grinder, wash it clean, and then divide it into an upper cover plate and a lower plate.

[0045] S4. Place the lower plate obtained in step S3 on the bonding fixture, and use an automatic glue applicator to apply polyurethane structural adhesive to the upper surface of the lower plate with a thickness of 0.1 mm.

[0046] S5. Cut the round tube (a scrap carbon fiber round tube for fishing rods) and the irregular part (a scrap carbon fiber irregular part for automobiles) to a fixed length of 20mm. After grinding to remove burrs, clean them to obtain a support column with a width of 20mm.

[0047] S6. The support columns obtained in several steps S5 are placed vertically and evenly arranged on the lower plate after step S4 to form an intermediate layer. The bonding area between the support columns and the lower plate is 10% of the area of ​​the lower plate.

[0048] S7. Apply polyurethane structural adhesive to the lower surface of the upper cover plate obtained in step S3, with a coating thickness of 0.1 mm, and then place it on the upper surface of the support column and press it firmly. The bonding strength between the support column and the upper cover plate / lower plate is 0.2 MPa.

[0049] S8. Once the structural adhesive on the lower plate and upper cover plate has cured, a semi-finished product is obtained. The semi-finished product is placed on a winding machine for wet winding of carbon fiber to form a winding layer. The fiber winding angle is 60 degrees and the thickness of the winding layer is 2mm. After the fiber winding is completed, it is transferred to an oven and cured at 120℃ for 1 hour. After demolding, it is trimmed to obtain a high-strength beam. Example

[0050] To manufacture a high-strength beam, follow these steps:

[0051] S1. Recycled carbon fiber materials are classified into three categories according to their shape: flat parts, round tube parts, and irregularly shaped parts;

[0052] S2. Cut the flat plate (a scrapped carbon fiber flat plate used for wind turbine blades) into two flat plates with a width of 50mm, a length of 1000mm, and a thickness of 5mm.

[0053] S3. After grinding the flat plate material obtained in step S2 in a flat plate grinder, wash it clean, and then divide it into an upper cover plate and a lower plate.

[0054] S4. Place the lower plate obtained in step S3 on the bonding fixture, and use an automatic glue applicator to apply epoxy structural adhesive to the upper surface of the lower plate with a thickness of 0.2mm.

[0055] S5. Cut the round tube (a scrapped carbon fiber round tube for fishing rods) and the irregular part (a scrapped carbon fiber irregular part for automobiles) to a fixed length of 10mm. After grinding to remove burrs, clean them to obtain a support column with a width of 10mm.

[0056] S6. The support columns obtained in several steps S5 are placed vertically and evenly arranged on the lower plate after step S4 to form an intermediate layer. The bonding area between the support columns and the lower plate is 20% of the area of ​​the lower plate.

[0057] S7. Apply epoxy structural adhesive to the lower surface of the upper cover plate obtained in step S3, with a coating thickness of 0.2 mm, and then place it on the upper surface of the support column and press it firmly. The bonding strength between the support column and the upper cover plate / lower plate is 0.1 MPa.

[0058] S8. Once the structural adhesive on the lower plate and upper cover plate has cured, a semi-finished product is obtained. The semi-finished product is placed on a winding machine for dry winding of glass fiber to form a winding layer. The fiber winding angle is 70 degrees and the thickness of the winding layer is 3mm. After the fiber winding is completed, it is transferred to an oven and cured at 90℃ for 3 hours. After demolding, it is trimmed to obtain a high-strength beam. Example

[0059] To manufacture a high-strength beam, follow these steps:

[0060] S1. Recycled carbon fiber materials are classified into three categories according to their shape: flat parts, round tube parts, and irregularly shaped parts;

[0061] S2. Cut the flat plate (a scrapped carbon fiber flat plate used for wind turbine blades) into two flat plates with a width of 50mm, a length of 1000mm, and a thickness of 5mm.

[0062] S3. After grinding the flat plate material obtained in step S2 in a flat plate grinder, wash it clean, and then divide it into an upper cover plate and a lower plate.

[0063] S4. Place the lower plate obtained in step S3 on the bonding fixture, and use an automatic glue applicator to apply epoxy structural adhesive to the upper surface of the lower plate with a thickness of 0.2mm.

[0064] S5. Cut the round tube (a scrapped carbon fiber round tube for fishing rods) and the irregular part (a scrapped carbon fiber irregular part for automobiles) to a fixed length of 50mm. After grinding to remove burrs, clean them to obtain a support column with a width of 50mm.

[0065] S6. The support columns obtained in several steps S5 are placed vertically and evenly arranged on the lower plate after step S4 to form an intermediate layer. The bonding area between the support columns and the lower plate is 30% of the area of ​​the lower plate.

[0066] S7. Apply epoxy structural adhesive to the lower surface of the upper cover plate obtained in step S3. The coating thickness is 0.2 mm. Then place it on the upper surface of the support column and press it firmly. The bonding strength between the support column and the upper cover plate / lower plate is 0.3 MPa.

[0067] S8. Once the structural adhesive on the lower plate and upper cover plate has cured, a semi-finished product is obtained. The semi-finished product is placed on a winding machine for wet winding of glass fiber to form a winding layer. The fiber winding angle is 45 degrees and the thickness of the winding layer is 1mm. After the fiber winding is completed, it is transferred to an oven and cured at 100℃ for 2 hours. After demolding, it is trimmed to obtain a high-strength beam.

[0068] The bending loads of the high-strength beams obtained in Examples 1-4 were measured according to GB / T 1449-2005 (Test for Bending Properties of Fiber Reinforced Plastics). The test results are shown in the table below:

[0069] Bending load (t) Example 1 1.5 Example 2 1.3 Example 3 1.4 Example 4 1.2

[0070] As can be seen from the table above, the high-strength beams obtained in Examples 1-4 of the present invention all have high bending loads, indicating that the high-strength beams prepared by the present invention have good bending performance.

[0071] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A method for manufacturing high-strength beams using recycled carbon fiber materials, characterized in that: Includes the following steps: S1. Recycled carbon fiber materials are classified into three categories according to their shape: flat parts, round tube parts, and irregularly shaped parts; S2. Cut the flat part into flat sheet materials; S3. After grinding the flat plate material obtained in step S2 in a flat plate grinder, wash it clean, and then divide it into two groups, one group is the upper cover plate and the other group is the lower plate. S4. Place the lower plate obtained in step S3 on the bonding fixture and apply structural adhesive to the upper surface of the lower plate. S5. Cut round pipes and irregular-shaped parts to a fixed length, grind to remove burrs, and then clean them to obtain support columns; S6. Place the support columns obtained in several steps S5 vertically and arrange them evenly on the lower plate after step S4 to form an intermediate layer. S7. Apply structural adhesive to the lower surface of the upper cover plate obtained in step S3, then place it on the upper surface of the support column and press it firmly. S8. Once the structural adhesive on the lower plate and upper cover plate has cured, a semi-finished product is obtained. The semi-finished product is placed on a winding machine to form a winding layer. After the fiber winding is completed, it is transferred to an oven for curing. After demolding, it is trimmed to obtain a high-strength beam.

2. The method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S1, the recycled carbon fiber material is one or more of the following: scrapped carbon fiber flat plates used for wind turbine blades, scrapped carbon fiber round tubes used for fishing rods, scrapped irregularly shaped carbon fiber parts used for automobiles, and other scrapped carbon fiber parts.

3. The method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S2, the ratio of the width to the thickness of the flat sheet is 10:

1.

4. The method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S4, the structural adhesive is a polyurethane structural adhesive or an epoxy structural adhesive, and the coating thickness of the structural adhesive is 0.1 to 0.2 mm.

5. A method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S5, the width of the support column is 10-50 mm.

6. The method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S6, the bonding area between the support column and the lower plate is 10-30% of the area of ​​the lower plate.

7. A method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S7, the bonding strength between the support column and the upper cover plate / lower plate is 0.1 to 0.3 MPa.

8. A method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S8, the fiber winding is either wet winding or dry winding, the fiber winding angle is 30 to 70 degrees, and the thickness of the winding layer is 1 to 3 mm.

9. A method for manufacturing high-strength beams using recycled carbon fiber materials according to claim 1, characterized in that: In step S8, the curing temperature is 90–120°C and the curing time is 1–3 hours.

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