Method for manufacturing a pressure-retaining structure from recycled composite components and pressure-retaining pipes.

Abstract

A system, method, and apparatus for providing a low-permeability pressure-retaining structure from high-performance recycled composite materials such as polymer carbon fiber composites. One or more recycled scrap composite components are mechanically processed to form multiple fragments based on protected carbon fibers, and the multiple fragments are then formed into a pressure-retaining structure. The dispersion of the multiple fragments and fibers contained within generates a meandering effect that reduces the permeability of the pressure-retaining structure, making the pressure-retaining structure suitable for transporting and storing gases and other fluids that may corrode conventional steel pressure structures.

Description

Technical Field

[0001] 1. Field Embodiments of the present disclosure relate to low-permeability structures. More specifically, embodiments of the present disclosure relate to forming low-permeability structures from recycled composite materials.

Background Art

[0002] 2. Related Art To contain pressurized fluids, pressure-containing structures such as tubing, valves, and connectors related thereto have been used. However, typical steel pipes contained within pressurized piping for transporting fluids such as gaseous hydrogen and carbon dioxide tend to corrode and fragment, for example, due to reaction with hydrogen. Therefore, within pressure-containing structures for hydrogen transport, composite materials have been used instead of metals. However, the cost of such composite materials is extremely high, and the manufacturing process for producing such composite materials is energy-intensive.

Summary of the Invention

Means for Solving the Problems

[0003] Embodiments of the present disclosure solve the above problems by providing a non-corrosive and low-permeable pressure-containing structure produced from recycled composite materials. Scrap parts containing composite materials are recycled via mechanical recycling to produce a plurality of fragments such that the fibers within the fragments are maintained.Next, the fragments are formed into a final structure such as a pressure-containing tube or other pressure-containing structure, in which the maintained fibers generate a meandering path, thereby assisting in reducing the permeability of the final structure.

[0004] In some embodiments, the technique described herein is a method for producing a pressure-retaining structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material; mechanically processing the one or more recycled parts into a plurality of fragments having a random fiber dispersion; and forming the plurality of fragments into a pressure-retaining structure through a forming process, thereby producing a pressure-retaining structure, wherein the random fiber dispersion of the plurality of fragments generates a meandering effect, thereby resulting in low gas permeability for the pressure-retaining structure to substantially contain a fluid within the pressure-retaining structure.

[0005] In some embodiments, the techniques described herein relate to a method for a carbon fiber composite material comprising carbon fiber polyether ether ketone, wherein the initial matrix of the carbon fiber composite material protects a plurality of short fibers placed therein.

[0006] In some embodiments, the techniques described herein relate to methods in which the forming process includes an extrusion process using an extruder apparatus.

[0007] In some embodiments, the techniques described herein relate to a method wherein the forming process comprises an additive manufacturing process using a 3D printer, and the method further comprises processing a plurality of fragments into a powder form comprising a plurality of granules having an average particle diameter of about 10 micrometers to about 100 micrometers, and providing the plurality of granules to a 3D printer.

[0008] In some embodiments, the techniques described herein further include selecting the fragment sizes of a plurality of fragments based on the pressure level associated with a pressure-retaining structure.

[0009] In some embodiments, the techniques described herein relate to methods in which the forming process includes an injection molding process using an injection mold.

[0010] In some embodiments, the techniques described herein further include forming a first layer of a pressure-retaining structure using first parts of a plurality of fragments, and forming a second layer of the pressure-retaining structure using second parts of a plurality of fragments.

[0011] In some embodiments, the technique described herein is a method for producing a pressure-retaining structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material; mechanically processing the one or more recycled parts to form a plurality of fragments; and fusing the plurality of fragments into a pressure-retaining structure, wherein the plurality of fragments are selectively oriented to produce a meandering effect, thereby resulting in low gas permeability for the pressure-retaining structure to substantially contain a fluid within the pressure-retaining structure.

[0012] In some embodiments, the techniques described herein relate to a method by which multiple fragments are fused into a pressure-retaining structure via an extrusion process using an extruder apparatus.

[0013] In some embodiments, the technique described herein further comprises forming a first layer of a pressure-retaining structure using first portions of a plurality of pieces selectively oriented in a first selected direction, and forming a second layer of the pressure-retaining structure using second portions of a plurality of pieces selectively oriented in a second selected direction different from the first selected direction.

[0014] In some embodiments, the techniques described herein further include forming a third layer of a pressure-retaining structure using a third portion of a plurality of fragments selectively oriented in a third selected direction different from a second selected direction.

[0015] In some embodiments, the techniques described herein relate to a method for mechanically processing one or more recycled parts, comprising feeding one or more recycled parts to a cutting device, the cutting device being configured to cut one or more recycled parts along axes parallel to the fiber direction of multiple fibers of a carbon fiber composite material, thereby forming multiple fragments while preserving multiple fibers.

[0016] In some embodiments, the techniques described herein further include adding additional carbon fiber material to a plurality of fragments.

[0017] In some embodiments, the techniques described herein further include adding additional polymer material to a plurality of fragments before forming a pressure-retaining structure.

[0018] In some embodiments, the technology described herein relates to a pressure-storage pipe comprising a carbon fiber polyether ether ketone (PEEK) material configured to provide a low-permeability pressure seal for containing a fluid inside the pressure-storage pipe, and a plurality of fused mechanically recycled fragments comprising the carbon fiber PEEK material, wherein the carbon fiber PEEK material has a random fiber dispersion that generates a meandering effect, thereby reducing the permeability of the pressure-storage pipe.

[0019] In some embodiments, the technology described herein relates to a pressure-storage pipe configured to contain a pressurized gaseous hydrogen fluid placed therein, wherein a carbon fiber PEEK material prevents corrosion of the pressure-storage pipe.

[0020] In some embodiments, the technology described herein relates to a pressure-accommodating pipe in which the carbon fiber PEEK material contains carbon fibers at a concentration of 20% to 50% by volume.

[0021] In some embodiments, the technology described herein relates to a pressure-containing pipe that further includes a first layer of a carbon fiber PEEK material including one or more first fibers oriented in a first direction and a second layer of a carbon fiber PEEK material including one or more second fibers oriented in a second direction different from the first direction.

[0022] In some embodiments, the technology described herein relates to a pressure-containing pipe configured to contain a pressurized hydrogen fluid.

[0023] In some embodiments, the technology described herein relates to a pressure-containing pipe configured to contain a pressurized carbon dioxide fluid.

[0024] This summary is provided to introduce a simplified form of a series of concepts that will be further described below in the "Detailed Description of the Invention." This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will become apparent from the following detailed description of the embodiments and the accompanying drawings.

[0025] Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

Brief Description of the Drawings

[0026] [Figure 1] An exemplary flowchart of a composite recycling process is illustrated for some embodiments of the present disclosure. [Figure 2A] An exemplary diagram of the dispersion of selectively oriented fibers in a composite material is illustrated for some embodiments of the present disclosure. [Figure 2B] An exemplary diagram of the dispersion of randomly oriented fibers in a composite material is illustrated for some embodiments of the present disclosure. ​Illustrates an exploded view of an exemplary layered composite component, relating to some embodiments of the present disclosure. [Figure 4] Illustrates an exemplary tubing structure formed of a composite material, relating to some embodiments of the present disclosure. [Figure 5] Illustrates a diagram of an exemplary cutting system for generating fragments in a selectively oriented direction, relating to some embodiments of the present disclosure. [Figure 6] Illustrates an exemplary method for producing a pressure containment structure, relating to some embodiments of the present disclosure.

[0027] These drawings do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale; instead, emphasis is placed on clearly showing the principles of the present invention.

Mode for Carrying Out the Invention

[0028] The following detailed description refers to the accompanying drawings that illustrate specific embodiments in which the present invention can be implemented. These embodiments are intended to explain aspects of the present invention in sufficient detail so that those skilled in the art can implement the present invention. Other embodiments can be utilized and modifications can be made without departing from the scope of the present invention. Therefore, the following detailed description should not be construed in a limiting sense. The scope of the present invention is defined only by the appended claims, together with the full scope of equivalents to which such claims are entitled.

[0029] In this description, any reference to “one embodiment,” “one embodiment,” or “multiple embodiments” means that the referenced feature or feature is included in at least one embodiment of the Art. Separate references to “one embodiment,” “one embodiment,” or “multiple embodiments” in this description do not necessarily refer to the same embodiment, nor are they mutually exclusive unless otherwise stated and / or is readily apparent to those skilled in the art from this description. For example, features, structures, operations, etc., described in one embodiment may, but not necessarily, be included in other embodiments. Thus, the Art may include various combinations and / or integrations of the embodiments described herein.

[0030] Polyether ether ketone (PEEK) is a high-performance thermoplastic material sought after due to its material properties, including chemical resistance over a wide temperature range, heat resistance, and excellent mechanical strength. PEEK has been used as a component in composite material applications. For example, PEEK can be reinforced with additives such as carbon fibers to further enhance its material properties without increasing its weight, and in some cases even reduce its overall weight. Composite materials such as carbon fiber reinforced PEEK exhibit improved properties compared to untouched PEEK material, including lightness, high strength, and low fluid permeability. In addition, high-temperature PEEK materials protect the internally suspended carbon fibers from shear during processing, handling, and high-temperature operation. However, such composite materials are typically costly to produce and rely on energy-intensive and time-intensive processes. Therefore, embodiments of this disclosure envision recycled composite materials that have already been produced and used. In some embodiments, scrap composite materials are recycled and reprocessed to form new structures without degrading their material properties. Furthermore, in some embodiments, the recycling manufacturing processes described herein result in improvements to certain material properties compared to the initial composite material.

[0031] Embodiments of the present disclosure result in a reduction of carbon production associated with the production of pressure-retaining structures. Specifically, the initial production of composite materials, such as the manufacture of carbon fibers and unidirectional tapes, generates large amounts of carbon dioxide and other pollutants such as trichloropropane (TCP). The manufacturing process also requires a great deal of energy due to the associated cooling and heating. By recycling composite materials that have already been produced and used, carbon production for producing new structures is significantly reduced. For example, embodiments of the present disclosure conceive of mechanically recycling components, including carbon fiber PEEK material, to maintain the material properties of high-performance composite materials without producing additional pollutants or relying on energy-intensive processes.

[0032] Embodiments of the present disclosure further conceivable the use of mechanically recycled composite materials to form pressure-retaining structures and other structures. In some embodiments, high-performance composite structures are recycled to take advantage of the benefits of the high-performance material without the costs associated with the production of new high-performance material. The recycled composite material is then processed into a plurality of fragments and formed into a new structure in either selectively oriented dispersion, random dispersion, or a combination thereof. For example, the fragments may be aligned to maintain dispersion in a particular favorable direction based on a particular application of the structure, or they may be randomly dispersed into various random orientations to result in a reduction in the fluid permeability of the structure due to meandering paths generated by the random orientation.

[0033] Figure 1 illustrates an exemplary flowchart of a composite recycling process 100 relating to several embodiments of the present disclosure. The composite recycling process 100 includes one or more recycled scrap components, such as scrap parts 102. Scrap parts 102 may include any form of recycled scrap components, such as recycled turbine blades, tubing, aircraft components and other aerospace components, unidirectional tapes, and other scrap components formed from composite materials.

[0034] In some embodiments, the scrap part 102 includes a composite material, such as a carbon fiber (CF) polyether ether ketone (PEEK) material. In some embodiments, the scrap part 102 includes a long fiber-reinforced thermoplastic composite, which includes a plurality of fibers arranged in a matrix extending over the length of the scrap part 102. The scrap part 102 is supplied to a mechanical recycling device 104, such as a grinder, shredder, or other suitable mechanical recycling device, which processes the scrap part 102 into a plurality of fragments 106. In some embodiments, the scrap part 102 is fed to the mechanical recycling device 104 to cut and shred the scrap part 102 into a plurality of fragments 106. In addition, in some embodiments, the plurality of fragments 106 may be returned to the mechanical recycling device 104 or another device for further processing any number of times. For example, the plurality of fragments 106 may be cut into smaller fragments.

[0035] In some embodiments, the multiple fragments 106 are further processed to refine them into multiple granules 108. For example, the multiple fragments 106 may be placed back into a mechanical recycling device 104 or another subsequent mechanical recycling device to further chop the multiple fragments 106 into smaller fibers. In one example, a series of mechanical recycling devices is conceivable in which each subsequent device processes the recycled fibers into smaller fragments. Additionally or alternatively, in some embodiments, a granulation process may be used to provide multiple granules 108 from a powder-based material. For example, the multiple fragments 106 may be ground and refined to form a powder material, which is then formed into granules via a granulation process. The multiple granules 108 may be in a diameter range of about 10 micrometers to about 100 micrometers. However, further embodiments are conceivable in which other size ranges may be used with respect to the multiple granules 108. However, in some embodiments, the multiple fragments 106 are not ground into a powder form in order to maintain the fibrous structure within the fragments.

[0036] In some embodiments, a plurality of fragments 106 are supplied to the extruder apparatus 110. Alternatively, in some embodiments, a plurality of granules 108 may be supplied to the extruder apparatus 110. The extruder apparatus 110 may be used to extrude either the plurality of fragments 106 or the plurality of granules 108 into an extruded part 112. Furthermore, in some embodiments, further processing steps may be applied to the plurality of fragments 106 before extrusion by the extruder apparatus 110. For example, the plurality of fragments 106 may be heated, and / or one or more adhesives, such as an adhesive or other suitable adhesive, may be added to the plurality of fragments 106. In some embodiments, unused PEEK material may be added to the plurality of fragments. Alternatively or additionally, other suitable thermoplastic polymer materials, such as polyetherimide (PEI) or polyamideimide (PAI), may be added. Furthermore, in some embodiments, adhesives and heat may be applied to the plurality of fragments 106 during the extrusion process. Other similar processes, such as injection molding, may use multiple fragments 106 to produce auxiliary or valve body components or piping, as well as other pressure-retaining and non-pressure-retaining structures of any suitable shape.

[0037] In some embodiments, the granules 108 can be further processed into a filament 114. For example, a similar extrusion process using an extruder device 110 may be used to extrude the granules 108 into the filament 114. Alternatively, in some embodiments, the fragments 106 are processed directly into the filament 114 without first forming the granules 108. For example, the fragments 106 can be extruded to form the filament 114. The filament 114 is supplied to an additive manufacturing device 116, such as a 3D printer or other suitable additive manufacturing device. Thus, the additive manufacturing device 116 receives the filament 114 and provides an additively manufactured part 118. The additively manufactured part 118 contains the composite material present in the fragments 106. In addition, the additively manufactured part 118 retains the properties of the fragments 106 due to the fibers still present in the additively manufactured part 118.

[0038] In some embodiments, a plurality of fragments 106 are supplied to a sheet forming apparatus 120, such as a thermomechanical sheet forming press. The sheet forming apparatus 120 may be used to compress the plurality of fragments 106 to form a compressed sheet 122. The compressed sheet 122 may be used within a pressure-retaining structure. In some embodiments, a plurality of compressed sheets formed from a recycled scrap composite may be used to form a pressure-retaining structure. Furthermore, in some embodiments, the plurality of sheets may be layered to further reduce the permeability of the pressure-retaining structure. In some embodiments, the compressed sheet 122 may be used as an external cover or internal liner of a tubing structure.

[0039] Figure 2A illustrates exemplary diagrams of selectively oriented dispersions 200A of fragments within a composite material according to some embodiments of the present disclosure. The selectively oriented dispersions 200A comprise a plurality of fragments 202, which are selectively oriented in a particular direction in the case of the selectively oriented dispersions 200A. For example, the fragments 202 may be oriented in the longitudinal direction of a pressurized structure formed by the composite material. Furthermore, embodiments have been conceived in which a first portion of the plurality of fragments is oriented in a first selected direction, and a second portion of the plurality of fragments is oriented in a second selected direction different from the first direction. For example, the first portion of the fragments may be oriented longitudinally, while the second portion of the fragments is oriented transversely.

[0040] In some embodiments, each fragment 202 contains multiple fibers placed within it. For example, a fragment may contain a composite material such as PEEK with carbon fibers added internally. Thus, carbon fibers are contained within the fragment 202. In some embodiments, the fibers within the fragment 202 may be oriented in known directions within the fragment. For example, the fibers may be oriented along the length of each fragment 202. Alternatively, in some embodiments, the fibers may be oriented in unknown directions.

[0041] An exemplary gas molecule 204 is shown to visually depict the meandering path 206 of the gas molecule 204. The meandering path 206 outlines an exemplary permeation path for the gas molecule 204 to permeate the composite material. Thus, the fragment 202 obstructs the motion and permeation of the gas particle by providing an obstacle to the gas molecule so that the gas molecule cannot freely permeate the composite material. Due to the obstruction by the fragment 202 (and the fibers within the fragment), the permeability of the composite material is relatively low compared to a similar composite material that does not contain the fragment 202, has fibers oriented parallel to the permeation path, or otherwise has non-randomized fibers.

[0042] As used herein, the meandering effect refers to material meandering in a composite material caused by microstructural and macrostructural imperfections present within the composite material that create a barrier that obstructs fluid permeability. As described herein, the meandering path 206 generates a meandering effect that obstructs the movement of mass through the composite material. For example, the meandering effect reduces permeability by substantially preventing the movement of mass of a fluid contained within a structure containing the composite material. In some embodiments, the meandering effect may result from a combination of dispersion of multiple fragments and multiple fibers contained within, such as carbon fiber additives added to the PEEK material.

[0043] Figure 2B illustrates exemplary diagrams of random orientation dispersion 200B of fragments in a composite material according to some embodiments of the present disclosure. Random orientation dispersion 200B comprises a plurality of fragments 202 positioned in a random dispersion. For example, each fragment 202 may be oriented in a random direction within the composite material. Similar to selectively oriented dispersion 200A as described above, random orientation dispersion 200B may generate meandering pathways 206 for exemplary gas molecules 204. Furthermore, embodiments can be conceived in which the dispersion of a plurality of fragments 202 is selectively oriented in a plurality of different directions. For example, the fragments may be oriented in a variety of selected directions to enhance protection against shear and / or leakage of gas (and other fluids) through the fragments. Thus, by using fragments with selectively designed orientations, the properties of the resulting structure are less random and more predictable. Thus, the dispersion of fragments can be tailored to specific applications of the structure.

[0044] In some embodiments, with respect to randomly oriented dispersion 200B, the generated meandering paths 206 are more complex and therefore additionally hinder the permeation of gases and other fluids into the material, resulting in even lower permeability compared to selectively oriented dispersion 200A. However, due to the randomness of the dispersion, randomly oriented dispersion 200B may have less consistency in properties compared to selectively oriented dispersion 200A.

[0045] In some embodiments, an average fragment length may be selected for a plurality of fragments 106. For example, in some embodiments, an average fragment length of about 1 / 8 inch and an average fragment width of about 1 / 4 inch may be selected. In some embodiments, a maximum fragment length of about 3 / 4 inch is selected for the plurality of fragments 106. Alternatively, in some embodiments, plurality of fragments 106 of other dimensions are conceived. For example, in some embodiments, the average dimensions of the plurality of fragments 106 may be selected at least in part on one or more desired properties of the final structure, such as a desired pressure level associated with the pressure-retaining structure. For example, in some embodiments, an average fragment length of 1 / 2 inch may be selected to produce a certain permeability within the final structure. Furthermore, in some embodiments, the dimensions of the plurality of fragments 106 may be selected at least in part on the length of the fibers contained in the composite material, such that the length and width of the fragments are greater than the average fiber length in order to maintain the total length of the fibers in the fragments. In some embodiments, the arrangement and sizing of the plurality of fragments are selected to delay (or prevent) fluid diffusion through the resulting structure. Additionally or alternatively, the arrangement and size may be selected to maintain the flexibility of the structure and withstand stresses caused by internal pressure. In some such embodiments, shorter fiber lengths provide enhanced diffusion prevention and stress performance compared to longer fiber composites. In some embodiments, fiber length and fragment size may be controlled at least partially by a selected grinding process or other mechanical recycling techniques.

[0046] Figure 3 illustrates an exploded view of an exemplary layered composite material component 300 relating to several embodiments of the present disclosure. The layered composite material component 300 comprises one or more layers of compression composite material. For example, one or more layers of compression composite material may be formed by compressing a plurality of fragments 106. In some embodiments, the exemplary layered composite material component 300 comprises a first layer 302, a second layer 304, and a third layer 306. The first layer 302 comprises a plurality of fragments 106 aligned in a first selected direction.

[0047] In some embodiments, the exemplary layered composite material component 300 may be produced by pressing one or more layers of the fragment 106 together into one or more compressed flat material sheets, for example, using the sheet forming apparatus 120 described above with respect to Figure 1 or another preferred pressing process.

[0048] As shown, the first layer 302 includes a plurality of fragments selectively oriented in a first direction. The second layer 304 includes a plurality of fragments randomly oriented in a plurality of different directions. The third layer 306 includes a plurality of fragments 106 selectively oriented in a second direction different from the first direction. In some embodiments, as shown, the second direction is perpendicular to the first direction. In some embodiments, layer 304 may be added between two or more cross-wound layers to enhance adhesion and prevent crack formation. Furthermore, the dispersion of the second layer 304 prevents delamination of the structure by improving performance against interlaminar shear forces. In certain pressure-accommodating applications utilizing composite materials such as pipes or other structures, delamination and the formation of transverse cracks are the most prominent failure modes. Another potential failure mode is along preferred pathways of diffusion and leakage within the structure. Thus, the various orientations of fragments in layers 302, 304, and 306 enhance protection against the failure modes described above. Specifically, the various dispersions of fragments (and the fibers within them) and the resulting meandering pathways prevent diffusion and enhance performance against shear and delamination.

[0049] Alternatively or additionally, embodiments have been conceived in which a different number of layers are used, or in which one or more layers are oriented in a direction different from that shown. Furthermore, in some embodiments, the order of the layers may differ from that shown. For example, a first layer 302 may be compressed directly onto a third layer 306. Furthermore, in some embodiments, the exemplary layered composite material component 300 may include two or more layers in which a plurality of fragments 106 are each oriented in a random direction, for example, there may be multiple second layers 304. Furthermore, embodiments have been conceived in which extrusion or co-extrusion techniques are used to produce a lamination that matches the layered recycled composite material. For example, the extrusion technique may be arranged to extrude the recycled composite material having known material properties for one or more known axes of the resulting structure, such as pressure containment strength and shear strength. Here, the resulting structure may be formed based on one or more expected parameters of the operating environment of the resulting structure. For example, if the pressure-accommodating structure includes a high-pressure-accommodating pipe, the cross-sectional area of ​​the pipe may be increased via the extrusion process to enhance the pressure-accommodating properties of the pipe.

[0050] The exemplary layered composite material component 300 is described and shown as a rectangular sheet. However, it should be understood that the exemplary layered composite material component 300 may include different shapes. For example, in some embodiments, the layers may be made up of any of a variety of three-dimensional shapes. For example, in some embodiments, the exemplary layered composite material component 300 may include a hollow tube or other object.

[0051] Figure 4 illustrates exemplary tubing structures 400 formed from composite material according to some embodiments of the present disclosure. The tubing structure 400 includes a plurality of selectively oriented fibers 402 oriented in a direction parallel to the length of the tubing structure 400. The tubing structure 400 may be formed using recycled composite material by any preferred manufacturing process, such as one of the manufacturing processes shown with respect to Figure 1 and described above. For example, the tubing structure 400 may be formed by using an extruder device 110 to extrude a plurality of fragments 106 or a plurality of granules 108 into the tubing structure 400. Alternatively, in some embodiments, the tubing structure 400 may be formed by injection molding or co-extrusion. For example, the co-extrusion technique may be adapted to fit the laminate constituting the composite structure.

[0052] In some embodiments, as shown, a plurality of fibers 402 are selectively oriented in a particular direction. Alternatively, in some embodiments, the tubing structure 400 may include randomly oriented fibers oriented in random directions. In some embodiments, as will be described in more detail below with respect to Figure 5, selectively oriented fibers may be formed by a particular cutting process. Alternatively, randomly oriented fibers may be formed by mixing a plurality of fragments 106 or through natural mixing that occurs during a mechanical recycling process by a mechanical recycling device 104.

[0053] The tubing structure 400 further includes a hollow inner portion 404 extending along the length of the tubing structure 400. The hollow inner portion 404 may be configured to receive a fluid, such as a gas or liquid material. For example, in some embodiments, the tubing structure 400 is configured to contain pressurized hydrogen gas or a carbon fluid. Thus, the tubing structure 400 can be used as a pressure containment structure in gas transport, isolation, or other pressure containment systems. Composite materials, such as carbon fiber PEEK, are corrosion-resistant and therefore offer a longer useful life compared to steel pipes and pipe liners that corrode as a result of reacting with hydrogen. Furthermore, meandering paths produced from recycled composite materials substantially prevent the permeation of hydrogen or other fluids contained within the tubing structure 400. Thus, the tubing structure 400 can provide a low-permeability pressure seal for containing fluids inside a pressure containment pipe.

[0054] In some embodiments, the tubing structure 400 comprises any number of layers of composite material. For example, in some embodiments, the tubing structure 400 may be formed by curving two or more recycled composite material sheets in which fragments and fibers are oriented in one or more random directions or in selectively oriented directions.

[0055] In some embodiments, other forms of pressure-retaining structures can also be conceived. For example, the fabrication techniques described herein can be applied to produce pressure-retaining structures formed from recycled composite materials, such as valves, valve bodies, tubing connections, pipe liners, pipe covers, and other forms of pressure-retaining structures. Alternatively or additionally, embodiments can be conceived in which other structures other than pressure-retaining structures can be formed from the recycled composite materials described herein. For example, multiple fragments 106 can be formed into other structures to enhance structural integrity due to the orientation of the fibers contained within and / or based on the dispersion of individual fragments within the structure. As some examples, recycled carbon fiber PEEK composite materials described herein can be used to form frames, bars, poles, and other structural support structures. Furthermore, recycled carbon fiber PEEK can also be applied to chemical applications where the corrosion resistance of the carbon fiber PEEK material prevents corrosion of the structure. In yet another example, recycled carbon fiber PEEK material can also be applied to high-temperature applications, such as power production applications, where the thermal properties of the carbon fiber PEEK material are suitable for withstanding relatively high temperatures. Furthermore, the recycled carbon fiber PEEK material described herein may be used to form other types of structures not explicitly described herein.

[0056] Figure 5 illustrates a diagram of an exemplary cutting system 500 for generating fragments in a selectively oriented direction, relating to several embodiments of the present disclosure. It should be understood that the shown cutting system 500 is merely one example of a system for cutting a part into multiple fragments, and that various other forms of cutting systems and apparatus can also be conceived. In some embodiments, as shown, a scrap part 502 is positioned on the cutting platform of the cutting system 500. In some embodiments, the scrap part 502 includes a plurality of fibers 504 oriented in a particular direction on the scrap part 502.

[0057] In some embodiments, the cutting system 500 comprises one or more cutting devices 506 configured to cut a scrap part 502 into a plurality of cutting portions 508. Thus, it is possible to maintain the orientation of the plurality of cutting portions 508 based on a selected cutting direction of the cutting system 500. For example, the scrap part 502 may be positioned on a platform so that the fibers within the scrap part 502 are aligned with the cutting direction and fed into the cutting system to produce cut pieces of the scrap part 502.

[0058] In some embodiments, the cutting system 500 is configured to cut the scrap part 502 along an axis parallel to the direction of the multiple fibers 504 so as to maintain the multiple fibers 504 within the multiple cut portions 508. Additionally or alternatively, in some embodiments, lateral cutting is also conceived. For example, in some embodiments, each of the multiple cut portions 508 may be cut to a specific length, width, and height. Furthermore, in some embodiments, the cut portions 508 may be further processed into multiple fragments 106 as described above to form a new part.

[0059] In some embodiments, a similar cutting system may be used to cut recycled unidirectional tape into multiple tape fragments for reprocessing into new structures. However, it should be understood that different forms of cutting systems may be used. For example, a cutting system configured to cut unidirectional tape transversely may be used. In addition, using recycled composite materials reduces the high energy consumption associated with initially producing composite materials such as carbon fiber PEEK, as well as the high costs associated with such composite materials.

[0060] Figure 6 illustrates an exemplary method 600 for producing a pressure-retaining structure according to some embodiments of the present disclosure. The method 600 can be used to transform recycled scrap components into new structures, such as pressure-retaining structures with improved fluid permeability. Furthermore, by using mechanically recycled materials, the method provides a low-cost and low-energy-required process for producing new structures while minimizing the production of contaminants.

[0061] In step 602, at least one recycled part is received. The recycled part may include scrap material such as scrap part 102. For example, the recycled part may include scrap from wind turbine blades or aircraft, in addition to other suitable scrap parts. In some embodiments, the scrap material comprises a composite material such as a carbon fiber composite such as CF-PEEK.

[0062] In step 604, the recycled part is mechanically processed into multiple fragments. For example, the mechanical recycling process described above may be performed using a mechanical recycling device 104 to cut the recycled part into multiple fragments 106. Alternatively, the mechanical processing may utilize a cutting system 500, as described above, to maintain a specific orientation of the multiple fragments 106.

[0063] In step 606, the fragments are formed into a new structure through a forming process. For example, the new structure may be formed by extrusion, 3D printing, pressing, or any other suitable manufacturing process not expressly described herein. In some embodiments, forming the fragments into a new structure may include either applying heat to the fragments and applying pressure. For example, in some embodiments, heat may be applied to increase the flexibility of the composite material before formation. Furthermore, in some embodiments, the structure may be produced through a sheet forming process, such as by pressing the fragments 106 into a compression sheet 122. In some embodiments, the new structure is formed by fusing at least a portion of the fragments 106 together. For example, in some embodiments, the fragments are fused together by an extrusion process using an extruder, such as an extruder 110, as described above. In some embodiments, an initial resin matrix of PEEK material protects the internally suspended carbon fibers from thermal and structural damage during the mechanical recycling process in step 604 and the structure formation in step 606. Therefore, recycled CF-PEEK material can be processed without damaging the fibers, thereby maintaining the enhanced properties associated with the fibers within the recycled material.

[0064] In step 608, meandering paths are provided within the new structure to reduce the fluid permeability of the new structure. In some embodiments, the meandering paths may be generated based on the orientation of multiple fragments within the new structure. The meandering paths produce a meandering effect that reduces the permeability of the structure. Thus, the new structure may be used in pressure-containment applications to contain pressurized fluids while preventing the fluid from substantially permeating out of the structure. For example, the new structure may be used as tubing in subsea and onshore pipelines and isolation applications.

[0065] In some embodiments, additional steps may be included in method 600. For example, the recycled material may be further processed by further crushing or cutting the multiple fragments 106, or by adding additional fibers, microstructures, adhesives, or other additives to the recycled material. For example, in some embodiments, additional carbon fibers may be added after the scrap parts have been mechanically recycled into multiple fragments in order to increase the overall carbon fiber content of the material. For example, a second conversion of the CF-PEEK material may be performed to inject additional carbon fibers into the PEEK material, which provides additional resistance to mass transfer through the material (i.e., further strengthens meandering pathways). Furthermore, in some embodiments, the recycled material may be heated to separate any adhesives already present in the scrap parts. For example, the multiple fragments 106 may be heated to a temperature below the melting point of the composite material but not above the melting point of the adhesive additive to dissolve and separate the adhesive from the composite material. Furthermore, an additional step may be included in which the multiple fragments 106 are mixed before being formed in step 606. For example, multiple fragments 106 can be mixed together to further randomize the orientation of the multiple fragments 106 and the fibers contained within them.

[0066] In some embodiments, the method 600 further comprises an additional step of feeding one or more recycled parts to a cutting device, which is configured to cut one or more recycled parts along axes parallel to the fiber direction of multiple fibers of a carbon fiber composite material, thereby forming multiple fragments while retaining multiple fibers within the fragments. For example, the cutting system 500 described above may be used to cut recycled parts while retaining the fibers contained therein.

[0067] In addition, in some embodiments, various concentrations of carbon fibers in the composite material are conceived. For example, in some embodiments, the recycled structure comprises a carbon fiber PEEK composite material having a carbon fiber concentration of 20% to 50% by volume. However, in some embodiments, other concentrations of carbon fibers not expressly described herein are conceived. In some embodiments, additional carbon fibers may be added to multiple fragments 106 to achieve a higher concentration of carbon fibers than that of the scrap parts 102.

[0068] Many of the embodiments described above refer to the use of composite materials such as carbon fiber PEEK. However, it should be understood that other suitable composite materials other than PEEK may be used. For example, other polymers belonging to the polyaryletherketone (PAEK) family of thermoplastics, such as polyetherketone (PEKK) or polyetherketone (PEK), may be used. Alternatively or additionally, in some embodiments, other suitable polymers such as polyethyleneimine (PEI) or polyamideimide (PAI) may be used instead of PEEK. In some embodiments, additional polymer materials may be added to multiple fragments before forming the pressure-retaining structure. For example, any of PEEK, PEKK, PEK, PAI, and PEI, as well as other suitable polymers, may be added to multiple fragments to increase adhesion and / or to strengthen the resin matrix.

[0069] Clause 1. A method for producing a pressure-retaining structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material; mechanically processing the one or more recycled parts into a plurality of fragments having a random fiber dispersion; and forming the plurality of fragments into a pressure-retaining structure through a forming process, thereby producing the pressure-retaining structure, wherein the random fiber dispersion of the plurality of fragments generates a meandering effect, thereby resulting in low gas permeability for the pressure-retaining structure to substantially contain a fluid within the pressure-retaining structure.

[0070] Clause 2. The method according to Clause 1, wherein the carbon fiber composite material comprises carbon fiber polyether ether ketone, and the initial matrix of the carbon fiber composite material protects a plurality of short fibers placed therein.

[0071] Clause 3. The method according to either Clause 1 or Clause 2, wherein the forming process includes an extrusion process using an extruder apparatus.

[0072] Clause 4. The method according to any one of Clauses 1 to 3, wherein the forming process includes an additive manufacturing process using a 3D printer, and the method further comprises processing the plurality of fragments into a powder form comprising a plurality of granules having an average particle diameter of about 10 micrometers to about 100 micrometers, and providing the plurality of granules to the 3D printer.

[0073] Clause 5. The method according to any one of Clauses 1 to 4, further comprising selecting the size of the plurality of pieces based on the pressure level associated with the pressure-retaining structure.

[0074] Clause 6. The method according to any one of Clauses 1 to 5, wherein the forming process includes an injection molding process using an injection mold.

[0075] Clause 7. The method according to any one of Clauses 1 to 6, further comprising using first parts of the plurality of fragments to form a first layer of the pressure-retaining structure and using second parts of the plurality of fragments to form a second layer of the pressure-retaining structure.

[0076] Clause 8. A method for producing a pressure-retaining structure, the method comprising: receiving one or more recycled parts, wherein the one or more recycled parts include a carbon fiber composite material; mechanically processing the one or more recycled parts to form a plurality of fragments; and forming the pressure-retaining structure by fusing the plurality of fragments into the pressure-retaining structure, wherein the plurality of fragments are selectively oriented to produce a meandering effect, thereby resulting in low gas permeability for the pressure-retaining structure to substantially contain a fluid within the pressure-retaining structure.

[0077] Clause 9. The method according to Clause 8, wherein the plurality of fragments are fused into the pressure-retaining structure via an extrusion process using an extruder device.

[0078] Clause 10. The method according to either Clause 8 or Clause 9, further comprising: forming a first layer of the pressure-retaining structure using first portions of the plurality of pieces selectively oriented in a first selected direction; and forming a second layer of the pressure-retaining structure using second portions of the plurality of pieces selectively oriented in a second selected direction different from the first selected direction.

[0079] Clause 11. The method according to any one of Clauses 8 to 10, further comprising using third portions of the plurality of fragments selectively oriented in a third selected direction different from the second selected direction to form a third layer of the pressure-retaining structure.

[0080] Clause 12. The method according to any one of Clauses 8 to 11, wherein the mechanical processing of the one or more recycled parts includes feeding the one or more recycled parts to a cutting device, the cutting device being configured to cut the one or more recycled parts along axes parallel to the fiber direction of a plurality of fibers of the carbon fiber composite material, thereby forming the plurality of fragments while preserving the plurality of fibers.

[0081] Clause 13. The method according to any one of Clauses 8 to 12, further comprising adding additional carbon fiber material to the plurality of fragments.

[0082] Clause 14. The method according to any one of Clauses 8 to 13, further comprising adding additional polymer material to the plurality of fragments before forming the pressure-retaining structure.

[0083] Clause 15. A pressure-storage pipe comprising a carbon fiber polyether ether ketone (PEEK) material configured to provide a low-permeability pressure seal for containing a fluid inside the pressure-storage pipe, and a plurality of fused mechanically recycled fragments comprising the carbon fiber PEEK material, wherein the carbon fiber PEEK material has a random fiber dispersion that generates a meandering effect, thereby reducing the permeability of the pressure-storage pipe.

[0084] Clause 16. The pressure containment pipe according to Clause 15, wherein the pressure containment pipe is configured to contain a pressurized gaseous hydrogen fluid placed therein, and the carbon fiber PEEK material prevents corrosion of the pressure containment pipe.

[0085] Clause 17. A pressure-retaining pipe according to either Clause 15 or Clause 16, wherein the carbon fiber PEEK contains carbon fibers at a concentration of 20% to 50% by volume.

[0086] Clause 18. A pressure-retaining pipe according to any one of Clauses 15 to 17, further comprising: a first layer of carbon fiber composite material containing one or more first fibers oriented in a first direction; and a second layer of carbon fiber composite material containing one or more fibers oriented in a second direction different from the first direction.

[0087] Clause 19. The pressure-retaining pipe described in any one of Clauses 15 to 18, wherein the pressure-retaining pipe is configured to contain a pressurized hydrogen fluid.

[0088] Clause 20. The pressure-retaining pipe described in any one of Clauses 15 to 19, wherein the pressure-retaining pipe is configured to contain a pressurized carbon dioxide fluid.

[0089] Although the present invention has been described with reference to embodiments shown in the accompanying drawings, it should be noted that equivalents may be adopted and substituted herein without departing from the scope of the invention as described in the claims.

[0090] While various embodiments of the present invention have been described in this manner, those that are claimed to be novel and are desired to be protected by patent terminology include the following:

Claims

1. A method for producing a pressure-retaining structure, wherein the method is Receiving one or more recycled parts, wherein the one or more recycled parts include carbon fiber composite material, The process of mechanically processing one or more of the recycled parts into multiple fragments having random fiber dispersion, The process includes forming the plurality of fragments into the pressure-retaining structure through a forming process, thereby producing the pressure-retaining structure, A method wherein the random fiber dispersion of the plurality of fragments generates a meandering effect, thereby resulting in low gas permeability for the pressure-retaining structure to substantially contain a fluid within the pressure-retaining structure.

2. The carbon fiber composite material contains carbon fiber polyether ether ketone, The method according to claim 1, wherein the initial matrix of the carbon fiber composite material protects a plurality of short fibers placed therein.

3. The method according to claim 1, wherein the forming process includes an extrusion process using an extruder apparatus.

4. The forming process includes an additive manufacturing process using a 3D printer, and the method is The aforementioned multiple fragments are processed into a powder form containing multiple granules having an average particle diameter of approximately 10 micrometers to approximately 100 micrometers. The method according to claim 1, further comprising providing the plurality of granules to the 3D printer.

5. The method according to claim 1, further comprising selecting the fragment sizes of the plurality of fragments based on the pressure level associated with the pressure-retaining structure.

6. The method according to claim 1, wherein the forming process includes an injection molding process using an injection molding die.

7. The first portion of the plurality of fragments is used to form the first layer of the pressure-retaining structure, The method according to claim 1, further comprising using second portions of the plurality of fragments to form a second layer of the pressure-retaining structure.

8. A method for producing a pressure-retaining structure, wherein the method is Receiving one or more recycled parts, wherein the one or more recycled parts include carbon fiber composite material, Mechanically processing one or more recycled parts to form multiple fragments, The process includes forming the pressure-retaining structure by fusing the plurality of fragments into the pressure-retaining structure, A method comprising the above-mentioned plurality of fragments being selectively oriented to generate a meandering effect, thereby resulting in low gas permeability for the pressure-retaining structure to substantially contain a fluid within the pressure-retaining structure.

9. The method according to claim 8, wherein the plurality of fragments are fused into the pressure-retaining structure via an extrusion process using an extruder device.

10. Using first portions of the plurality of fragments selectively oriented in a first selected direction, a first layer of the pressure-receiving structure is formed; The method according to claim 8, further comprising forming a second layer of the pressure-receiving structure using second portions of the plurality of fragments selectively oriented in a second selected direction different from the first selected direction.

11. The method according to claim 10, further comprising forming a third layer of the pressure-retaining structure using third portions of the plurality of fragments selectively oriented in a third selected direction different from the second selected direction.

12. The method according to claim 8, wherein the mechanical processing of the one or more recycled parts includes feeding the one or more recycled parts to a cutting device, the cutting device is configured to cut the one or more recycled parts along axes parallel to the fiber direction of a plurality of fibers of the carbon fiber composite material, thereby forming the plurality of fragments while maintaining the plurality of fibers.

13. The method according to claim 8, further comprising adding additional carbon fiber material to the plurality of fragments.

14. The method according to claim 13, further comprising adding additional polymer material to the plurality of fragments before forming the pressure-retaining structure.

15. A pressure-storage pipe, A carbon fiber polyether ether ketone (PEEK) material configured to provide a low-permeability pressure seal for containing fluid inside the pressure-retaining pipe, The system includes a plurality of fused mechanically recycled fragments containing the aforementioned carbon fiber PEEK material, A pressure-retaining pipe having a random fiber dispersion in the carbon fiber PEEK material, which generates a meandering effect and thereby reduces the permeability of the pressure-retaining pipe.

16. The pressure-storage pipe according to claim 15, wherein the pressure-storage pipe is configured to contain a pressurized gaseous hydrogen fluid placed therein, and the carbon fiber PEEK material prevents corrosion of the pressure-storage pipe.

17. The pressure-storage pipe according to claim 16, wherein the carbon fiber PEEK material contains carbon fibers at a concentration of 20% to 50% by volume.

18. A first layer of the carbon fiber PEEK material comprising one or more first fibers oriented in a first direction, The pressure-storage pipe according to claim 15, further comprising: a second layer of carbon fiber PEEK material containing one or more second fibers oriented in a second direction different from the first direction;

19. The pressure-storage pipe according to claim 15, wherein the pressure-storage pipe is configured to contain a pressurized hydrogen fluid.

20. The pressure-storage pipe according to claim 15, wherein the pressure-storage pipe is configured to contain a pressurized carbon dioxide fluid.

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