Laser Resin Removal for FRP Recycling and Carbon Fiber Reuse
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Solution Overview
Problem
Current methods for repairing and recycling Fiber Reinforced Plastics (FRP), particularly Carbon Fiber Reinforced Plastics (CFRP), face challenges of high complexity, high cost, and the need for extensive facilities, with existing recycling methods involving extensive furnace heating and limited versatility.
Innovation Solution
A method utilizing a laser irradiation device with a laser light source and light collector to selectively remove thermosetting resin from FRP, exposing the carbon fibers, allowing for easy recycling and repair by irradiating laser beams in a predetermined pattern and direction to completely remove the resin in the thickness direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermosetting resin is removed by heating CFRP in a large furnace to burn plastic, then a large amount of waste CFRP can be processed, but extensive facility is required
Solution Approach 1:
The patent replaces the large-scale thermal combustion system (mechanical/thermal system) with a laser beam system. The laser beam directly ablates and removes thermosetting resin from CFRP at targeted locations without requiring extensive furnace facilities, thus substituting a complex mechanical thermal system with a more compact optical system that achieves similar resin removal functionality.
Solution Approach 2:
The patent extracts and removes only the thermosetting resin component from CFRP using laser irradiation, leaving the carbon fiber reinforcement intact. This selective extraction approach allows for targeted resin removal without processing the entire composite material structure, enabling simpler facilities compared to bulk combustion methods.
2Device complexity
If laser beam is used to remove thermosetting resin from FRP, then device complexity is reduced, but processing speed may be insufficient for large amounts of waste
Solution Approach 1:
The patent segments the resin removal process into multiple passes with different laser beam parameters. By dividing the removal into stages (initial removal, intermediate removal, final removal) with varying power levels and scanning speeds, the system efficiently processes large areas while maintaining control over the removal rate, thus increasing overall productivity without requiring extensive facilities.
Solution Approach 2:
The patent implements continuous laser beam scanning across the CFRP surface to remove thermosetting resin continuously rather than in discrete steps. This continuous action maximizes the utilization of the laser system's capability, maintaining high processing speed throughout the operation and improving overall productivity while keeping the device relatively simple.
3Ease of manufacture
If laser beam irradiation is applied to remove resin, then selective removal is achieved, but energy consumption increases
Solution Approach 1:
The patent employs periodic pulsed laser irradiation rather than continuous high-power irradiation. By using pulsed laser beams with optimized duty cycles, the system achieves selective resin removal through repeated short-duration energy applications, reducing overall energy consumption compared to continuous high-power laser operation while maintaining selective removal capability.
Solution Approach 2:
The patent dynamically adjusts laser beam parameters (power, pulse duration, scanning speed, wavelength) based on the specific requirements of different CFRP regions and resin types. By optimizing these parameters for each processing stage and target material, the system minimizes energy consumption while achieving effective selective resin removal, thus reducing the trade-off between selectivity and energy use.
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
Enables efficient and cost-effective recycling and repair of FRP by exposing only the fiber material, facilitating the reuse of carbon fibers and reducing the need for extensive facilities, while allowing for the formation of three-dimensional shapes and repair of damaged surfaces.
Implementation Method 1
irradiating a laser beam L on a surface T of a fiber reinforced plastic S having a thermosetting resin P
Implementation Method 2
the thermosetting resin is removed in the irradiated position, whereby the fiber material contained in the FRP is exposed
Data Source
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AI summary
A laser beam (L) is irradiated onto a surface (T) of FRP to remove thermosetting resin (P) in an irradiated position of the laser beam (L) such that fiber material contained in the FRP is exposed.