Carbon Fiber Realignment Using Oscillating Baffles
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Solution Overview
Problem
Current methods for recycling carbon fibers from composite materials result in fibers that are either too short or not aligned, making them unusable for reinforcing new composite materials, and the high cost of fiber/matrix separation processes is not financially balanced by the cost of processing waste, as only decimetric length fibers can utilize mechanical strength effectively.
Innovation Solution
A process and device that unweave and realign carbon fibers from fabric blanks using a combination of pressure rollers, oscillating alignment modules with inclined baffles, and a second module for shaping fibers into continuous strips, with the option to add a polymer binder for cohesion, allowing for the production of semi-finished products with aligned fibers suitable for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If carbon fibers are separated from composite materials using conventional methods, then fiber recovery is achieved, but the fibers become too short or misaligned to be useful for reinforcement
Solution Approach 1:
The patent employs dynamic oscillating movements of alignment modules with inclined baffles to realign fibers during the separation process. The oscillating motion prevents fiber entanglement and maintains fiber length while achieving precise alignment, resolving the contradiction between fiber alignment precision and fiber length preservation
Solution Approach 2:
The alignment modules utilize mechanical vibration through oscillating movements to facilitate fiber realignment without mechanical contact that would shorten fibers. The vibration helps fibers settle into aligned positions naturally, maintaining both length and alignment quality
2Ease of manufacture
If fiber/matrix separation processes are used to recover carbon fibers, then fiber reuse becomes possible, but the process cost is too high to be financially viable
Solution Approach 1:
The invention enables the recycling process to be financially self-sustaining by producing high-quality aligned fibers that can be sold as valuable semi-finished products. The process design ensures that the output quality justifies the processing cost, making the recycling operation economically viable without requiring external subsidies
Solution Approach 2:
The patent changes the quality parameters of recovered fibers through precise alignment, transforming them from unusable short fibers into valuable semi-finished products with decimeter lengths and high alignment. This parameter improvement increases market value and enables financial viability of the recycling process
3Loss of energy
If short carbon fibers are produced from recycled composites, then waste processing cost is reduced, but mechanical strength utilization is lost
Solution Approach 1:
The invention applies local quality enhancement by specifically targeting fiber alignment and length preservation in the regions where mechanical strength is critical. The alignment modules create localized conditions that maintain fiber integrity and orientation, ensuring that the recovered fibers retain their load-bearing capabilities
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 process effectively reshapes semi-long recycled carbon fibers into continuous strips with high realignment rates, enabling the exploitation of their mechanical resistance in future products and providing a financially balanced recycling method by producing valuable semi-finished products.
Implementation Method 1
a step of realigning said fibers by successive contacts on at least two walls of a first alignment module animated by an oscillating movement and presenting at least two baffles made up of planes inclined with respect to the vertical
Implementation Method 2
The fibers align as they fall through the first module, colliding with the baffles
Implementation Method 3
a step of laying the fabric cut onto an adhesive mat by means of a pressure roller
Implementation Method 4
The polymer binder ensures cohesion of the fibers
Data Source
Figure 1
Figure 2~3
Figure 2bis
AI summary
The present invention relates to a method for unweaving and realigning fibres, in particular carbon fibres, from fabric cuts with warp and weft yarns, characterised in that it comprises a step of realigning said fibres by successive impacts on at least two walls of a first alignment module (4) and a step of shaping by a second module (6). The realignment is carried out by a series of baffle plates (400) oriented at between 0 and +90°, and preferably at between +10° and +80°, relative to vertical. The fibres become aligned when falling through the first module (4), colliding with the baffles (400). The first module (4) has a vertical vibrating movement with a frequency of between 10Hz and 200Hz, for example to prevent any fibres from becoming stuck between the baffles (400). Since the movement is a vertical vibrating movement, it does not cause the fibres to become misaligned.