Continuous-Fiber Thermoplastic Composite Recycling With Resin Recoating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current recycling processes for fiber glass composites fail to maintain fiber length, are not cost-effective, and result in a high CO2 footprint, leading to the incineration of these materials and environmental waste.
Innovation Solution
A method involving heating and twisting a recycled thermoplastic continuous-fiber tape, threading it through dies, and applying a second molten resin to produce a continuous-fiber reinforced thermoplastic composite, which is then cooled and optionally cut into granules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grinding and shredding is used to recycle fiber glass composites, then the composites can be processed, but the glass fibers are destroyed and can only be used as filler
Solution Approach 1:
The patent extracts the continuous fibers from the composite structure by dissolving the thermoplastic matrix through heating and chemical treatment, separating the valuable fibers from the waste material. This allows the fibers to be recovered intact for reuse in new composite applications
Solution Approach 2:
The patent changes the physical and chemical parameters of the composite material by heating it to specific temperatures and applying chemical treatments that selectively dissolve the thermoplastic matrix while preserving the fiber structure. This transforms the composite from an unusable waste form into separable components with retained fiber properties
2Use of energy by moving object
If incineration is used to process fiber glass composites, then energy can be generated, but the fibers are lost and ash is produced that must be landfilled
Solution Approach 1:
The patent converts the previously harmful incineration process into a beneficial recovery process by using controlled heating and chemical treatment to dissolve the matrix and extract the fibers. Instead of destroying the material, the process recovers the valuable fiber component for reuse, turning waste into a reusable resource
3Productivity
If current recycling processes are used for glass fiber reinforced plastics, then some material can be recovered, but fiber length is not maintained and the process is not cost effective
Solution Approach 1:
The patent maintains the continuity of the fiber structure throughout the recycling process by using methods that preserve fiber integrity. The heating and chemical treatment approaches are designed to dissolve the matrix without fragmenting the fibers, maintaining their continuous nature and length for reuse in high-value applications
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
This method maintains fiber length, reduces waste, is environmentally friendly, and produces composites with mechanical properties comparable to virgin materials, while being cost-effective.
Implementation Method 1
applying in the chamber the second thermoplastic resin to the intermediate continuous-fiber thermoplastic material to obtain a coated intermediate continuous-fiber thermoplastic material
Data Source
AI summary
A method of manufacturing a continuous-fiber reinforced thermoplastic composite comprising the steps ofa) providing and heating a recycled thermoplastic continuous-fiber tape comprising a first thermoplastic resin to obtain a heated recycled thermoplastic continuous-fiber tape;b) threading the heated recycled thermoplastic continuous-fiber tape through a first die to obtain an intermediate continuous-fiber thermoplastic material;c) feeding the intermediate continuous-fiber thermoplastic material through a chamber filled with a second molten thermoplastic resin, wherein the chamber is connected to an extruder;d) applying in the chamber the second thermoplastic resin to the intermediate continuous-fiber thermoplastic material to obtain a coated intermediate continuous-fiber thermoplastic material and threading the coated continuous-fiber thermoplastic composite material through a second die to obtain a continuous-fiber reinforced thermoplastic composite;e) cooling the continuous-fiber reinforced thermoplastic composite.