Fiber Recycling Binder Coating to Prevent Entanglement
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Solution Overview
Problem
Current recycling methods for fiber-reinforced plastics, such as pyrolysis and grinding, result in degraded fibers due to entanglements and pilling, making it difficult to reintroduce them into the production cycle, especially for defective or end-of-life components.
Innovation Solution
A method involving the separation of matrix-bonded fibers into free fibers, followed by coating with a binder to prevent entanglements, and aligning them to maintain original fabric structure and orientation, allowing for the production of high-quality recycled fibers that can be reused in new components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pyrolysis and grinding processes are used to separate fibers from matrix material, then fiber separation is achieved, but fiber quality degrades due to entanglements and pilling
Solution Approach 1:
The patent applies preliminary action by coating fibers with a binder immediately after separation from the matrix material, before entanglements and pilling can occur. This preventive coating action protects the fibers during subsequent handling and processing, maintaining their quality without requiring post-processing remediation.
Solution Approach 2:
The binder acts as an intermediary substance between the separated fibers and the handling process. It coats the fibers to prevent direct contact and friction that cause entanglements and pilling, while allowing the fibers to be processed further. The binder mediates the interaction between fibers and processing equipment, reducing harmful effects.
2Productivity
If fibers are ground after separation to reintroduce them into the material cycle, then recycling is enabled, but fiber quality degrades
Solution Approach 1:
The binder coating is applied as a preliminary protective measure before fibers undergo any further processing including grinding. This pre-protection enables the recycling process to proceed while minimizing quality degradation, allowing fibers to be reintroduced into the material cycle with acceptable quality.
Solution Approach 2:
The patent changes the physical-chemical parameters of the fiber surface by applying a binder coating. This modification alters the surface properties to reduce friction and prevent entanglements during handling and grinding, enabling recycling while preserving fiber quality through parameter modification rather than mechanical alteration alone.
3Device complexity
If fibers are separated without binder coating to maintain simplicity, then process complexity is reduced, but entanglements and pilling occur
Solution Approach 1:
The binder serves as a simple intermediary substance that can be applied through straightforward coating methods. It prevents entanglements and pilling without requiring complex equipment or multi-step processes, adding minimal complexity while effectively solving the harmful fiber interaction problem.
Solution Approach 2:
The binder coating can be viewed as a disposable protective layer that is applied, serves its protective function during handling, and can be removed or remains as a minimal residue. This approach uses a simple, consumable substance rather than complex permanent modifications to the fiber or equipment.
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 enables the recycling of fiber-reinforced components by preventing entanglements and maintaining fiber quality, allowing for the efficient reuse of fibers in new products with improved mechanical properties and reduced resource consumption.
Implementation Method 1
coating with a binder to prevent entanglements
Implementation Method 2
pyrolysis for dissociation of the plastic matrix at temperatures above 350° C. into smaller organic molecules which evaporate
Implementation Method 3
dissociation of the plastic matrix at temperatures above 350° C. into smaller organic molecules which evaporate
Implementation Method 4
the matrix conventionally has a stronger absorption of electromagnetic waves, this leads to a selective heating of the matrix, which leads to decomposition of the matrix and the separation of fibers and matrix
Implementation Method 5
input of energy into the recycled fiber composite material via electromagnetic waves, especially microwaves
Data Source
AI summary
The present invention relates to a recycling process for recycling fiber-reinforced and/or fiber based semi-finished products and/or components for later use in the production of fiber-reinforced and/or fiber based semi-finished products and/or components, wherein the semi-finished products and/or components are comprised of fibers and a matrix material, and the fibers are arranged in the matrix material in the form of a fabric, unidirectional layers and/or plies and/or individual reinforcing fibers and/or reinforcing fiber bundles, and further, a device for carrying out the recycling process.