Carbon Fiber Composite Processing for High Recycled Fiber Dispersion

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Solution Overview

Problem

Existing methods struggle to produce carbon fiber composite materials with high strength and elasticity using recycled carbon fibers due to poor mechanical characteristics and low dispersibility, leading to agglomeration and degradation of material properties.

Innovation Solution

Applying a shearing force and stretching force during the melting and kneading process using a twin-screw kneader with specific configurations to disperse recycled carbon fibers at high concentrations (50-70 wt%) within a resin, resulting in a well-dispersed composite material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If recycled carbon fibers are used to produce carbon fiber composite materials, then cost is reduced and environmental burden is alleviated, but mechanical characteristics (strength and elasticity) deteriorate

Engineering Contradiction:

ImprovecostVSAvoidmechanical characteristics

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention changes the physical parameters of recycled carbon fibers through controlled shortening of fiber length and adjustment of aspect ratio to optimize mechanical properties. By controlling fiber length to specific ranges and adjusting the aspect ratio, the composite material achieves improved strength and elasticity while maintaining cost advantages of using recycled fibers.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite material system combining resin matrix with specifically processed recycled carbon fibers. The composite structure leverages the resin to bind and protect the recycled fibers, while the controlled fiber morphology optimizes load transfer and mechanical performance, achieving both economic and mechanical goals.

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If recycled carbon fibers are blended at high concentration, then cost is reduced, but dispersibility deteriorates and agglomeration occurs

Engineering Contradiction:

Improvefiber concentrationVSAvoiddispersibility

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The invention changes the morphological parameters of recycled carbon fibers by controlling fiber length and aspect ratio. By shortening fibers to optimal lengths and adjusting aspect ratios, the fibers achieve better dispersion at high concentrations while maintaining structural integrity and preventing agglomeration in the composite material.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If fiber length is shortened during kneading, then dispersibility is improved, but mechanical strength may be reduced

Engineering Contradiction:

ImprovedispersibilityVSAvoidmechanical strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The invention optimizes fiber length parameters within specific ranges that balance dispersibility and strength. Rather than excessive shortening, the process controls fiber length reduction to achieve optimal values that enable good dispersion while maintaining sufficient length for effective load transfer and mechanical reinforcement.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies partial shortening action during kneading - enough to improve dispersibility and reduce agglomeration, but controlled to avoid excessive shortening that would compromise mechanical strength. The aspect ratio control ensures sufficient fiber length is maintained for structural integrity.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method achieves high strength and elasticity in the composite material while suppressing anisotropy, allowing for isotropic molded bodies with improved mechanical characteristics.

Implementation Method 1

a shearing force is applied to the raw material by the screw main body

Methodology Applied

Scientific EffectShearing force: Shear Stress

Implementation Method 2

a stretching force is applied to the raw material by passing the raw material from an inlet of the passage provided on the outer circumferential surface to an outlet of the passage

Methodology Applied

Scientific EffectStretching force: Tension

Implementation Method 3

a method for producing a carbon fiber composite material by melting, kneading and continuously discharging a raw material containing a resin and recycled carbon fibers

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250353225A1Method for producing carbon fiber composite material

Publication Date: 2025.11.20 SHIBAURA MASCH CO LTD

AI summary

Provided is a method for producing a carbon fiber composite material having high strength and elasticity and containing recycled carbon fibers. When a raw material is transported along the outer circumferential surface of a screw main body 37 having a passage 88 therein, the transport of the raw material is restricted by a barrier portion 82 provided on the outer circumferential surface, a shearing force is applied to the raw material by the screw main body 37, and a stretching force is applied to the raw material by passing the raw material from the inlet 91 of the passage 88 provided on the outer circumferential surface to the outlet 92 of the passage 88, thereby shortening a fiber length of the recycled carbon fibers and obtaining a carbon fiber composite material having good strength and elasticity and containing 50-70 wt % of recycled carbon fibers well dispersed therein.